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In the present article, the effect of friction stir welding (FSW) parameters on the weldability and the characteristics of dissimilar weld of aluminum alloys, called AA2024-T4 and AA7075-O are investigated. A number of FSW experiments are carried out to obtain high-quality welds by adjusting the rotational and welding speeds. The weldability and blending of two materials are evaluated by using the macrostructural analysis to observe whether making a notch in a threaded cylindrical tool will lead to a better blend rather than the threaded taper tool or it will have no effects. The mechanical properties of the welds are studied through microhardness distribution and tensile tests. Furthermore, the microstructure analysis is performed to study the influence of the pin profile and the rotational speed on the grain size. Moreover, in the present study, one of the most major goals is to obtain high-quality welds by spending as little expenditure as possible. Therefore, it prevents using complicated and insupportable high welding speed equipments.

This research presents the effect of welding speed on dissimilar joints of AA7075-T6 and AA6061-T6 alloys. The weld quality was evaluated through observations of the macrostructure. The mechanical properties of the welds, including the ultimate strength, the percentage of elongation, and the microhardness variations, were determined for different welding speeds. Also the effect of the positions of the two alloys on the mechanical properties was investigated. In addition, during the friction stir welding (FSW) process, the peak temperatures were measured in order to indicate the relation between the peak temperature and the hardness distribution at the heat-affected zone (HAZ). Accordingly, the influence of the welding speed on the developed grain size was elucidated by the microstructural analysis.

In this paper, the material behaviour and mechanical characteristics of lap joint friction stir welding (FSW) between dissimilar alloys, namely, Cu and Al, is investigated. In order to produce welds of a higher quality, a layer of Cu is anodised on the aluminium alloy. The mechanical and the microstructural characterisations are performed on the welds, which are produced using various welding parameters. Scanning electron microscope with energy dispersive X-ray spectroscopy is used to identify the elemental compositions of phases that are formed. The results reveal that the use of the copper anodised layer prevented formation of brittle intermetallic compounds due to the direct FSW of 6061 aluminium alloy to copper and, as a result, enhanced the weld metallurgical and mechanical properties.

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