In this research, microstructural events and mechanical behaviors in dissimilar friction stir welding (FSW) of aluminium (Al) alloy AA6082-AA7075 joints have been evaluated to apply aerospace, defense, and military sectors. FSW parametric effects have a more significant impact on the mechanical performances and microstructure of produced joints. FSW tool rotational speed, welding speed, and tool plunge speed were chosen to make the weld joints. The rotational tool speeds of 1600 rpm and 2300 rpm, welding speeds of 40 mm/min and 60 mm/min, and tool plunge speeds of 20 mm/min and 30 mm/min were set as the upper and lower limits. A constant axial force of 5 kN was maintained throughout the joint fabrication process. A taper pin-profiled tool was utilized to produce the butt welded joints. Mechanical properties of microhardness, tensile strength, yield strength, elongation, and bending strength of the joints were analyzed. The response of the stir zone microstructure to processing parameters was evaluated using optical microscopy (OM) and fractographic analysis of a tensile specimen shown by scanning electron microscope (SEM). The weld joints produced at 2300 rpm, tool traveling rate of 40 mm/min, and tool plunge speed of 30 mm/min showed the greatest tensile strength of the 191 MPa hardness of 145 Hv at the weld center and also the maximum bending strength of 114.23 N/mm2 was achieved. The lowest bending strength of 25.38 N/mm2 was obtained at 1600 rpm with 60 mm/min due to inappropriate mixing of the base metals and poor joint quality. Furthermore, this study revealed that a higher tool plunge speed facilitates the formation of equiaxed grains in the thermomechanically affected zone (TMAZ) on the advancing side (AS). Additionally, the increment in tool rotational speed significantly improved the tensile strength, weld joint quality, and joint efficiency.
Friction stir welding (FSW) factors significantly impact the welding characteristics of AA 8011 and similar alloys weld joints produced by FSW. The tool pin profiles influence joint characteristics, weld quality, and joint strength. This study used three tool pin profiles to create weld connections at three different tool rotation rates and various welding speeds. Design of experiments (DOE) was utilized to execute complete full factorial experiments. The welded joints’ mechanical characteristics were examined using hardness and tensile tests at room temperature. The average maximum hardness number was 38.28 HRB with the tapered tool at 1300 rpm spindle speed and welding speed of 20 mm/min at 5 kN unvarying axial force of the whole operation. The lowest hardness value was 30 HRB using a taper threaded pin profile tool, rotating at 1200 rpm and welding at 60 mm/min. When the taper pin profile tool was used at 1500 rpm, the highest tensile strength of the weld joint was achieved, which was the closest value of the parent material. At the same welding speed of 20 mm/min, the taper threaded pin tool at 1300 rpm produces the lowest tensile strength of 84.16 MPa, made utilizing a taper threaded pin tool.
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