Experimental Study of Mechanical and Metallurgical Properties of Friction Stir Welded Dissimilar Aluminum Alloys

Friction stir welding is a comparatively quiet new solid state metal joining process developed by the Welding Institute in 1991 and is used for joining of aluminum alloys and dissimilar materials which were difficult to using conventional welding. Objective of this work is to produce sound weld of dissimilar aluminum alloy of AA7075 and AA6101 by using FSW process with two different tool pin profile and investigate the mechanical and metallurgical properties such as tensile Strength, impact strength and microstructure in terms of Process parameters such as tool Rotational speed, tool transverse speed and axial force. Better mechanical properties were obtained at a tool rotational speed of 1200 rpm, transverse speed 45mm/min and axial force of 6KN. Better mechanical and metallurgical properties were obtained by the joint made by straight cylindrical tool pin profile. This study was focused on process parameters and suitable tool profile that necessary for fabricating superior welded joints.