The study presents the hybrid joining of the third generation AA2198-T8 aluminum lithium alloy to AA2024-T3 aluminum copper alloy, which has been highly demanded recently in the aerospace industry. This investigation aims to reduce the cost of production in the industrial sector. As a result, an affordable alternative is to use hybrid designs using AA2198-T8 alloy in crucial parts and AA2024-T3 alloy in the rest of the structure. A joining method is required to create hybrid structures composed of last-generation and standard aluminum alloys. The joining process was successfully friction stir-welded using five different welding travel speeds—36, 76, 102, 146, and 216 mm/min—with an invariable spindle speed of 960 rev/min. Two reversed steps, double-sided friction stir welding (DS-FSW) and single-sided friction stir welding (SS-FSW) techniques with two appropriate tool designs, were employed to investigate the dissimilar material mechanical properties and their morphological changes. The experimental outcomes show that DS-FSW of the reversed steps has a higher joining strength than SS-FSW for all the welding parameters studied. The variation in travel speeds provided the highest strength at 102 mm/min travel welding speeds for DS-FSW. Therefore, it is found that, from the three tensile samples, tensile strength, yield strength, and elongation of the joint were 407.1 MPa, 271.2 MPa, and 9.5%, respectively. The joint efficiency reached 87% compared with the base material tensile strength of AA2024-T3. Furthermore, fractures of the tensile samples were found in the vicinity of the thermomechanically affected zone (TMAZ) of the AA2198-T8 side. The microhardness and morphology results correspondingly have precise predictions for the fracture zone of the joints in this research examination.

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Friction stir welding is used to evaluate the metallurgical and material characteristics of AA2198-T8 and AA2024-T3 welds. One of the most often utilised high-strength aluminium alloys in the aerospace industry is AA2024-Tx. The latest generation of aluminium lithium alloys, AA2198-T8, just replaced AA2024-T3. Yet, sound weld methods with the highest mechanical qualities have yet to be adequately characterised. These two materials were selected and joined through two techniques. The first is a single side friction stir weld, while the second is a double side friction stir weld. This technique was used to create specimens by holding them side by side. After the stirring, the hybrid joint was created by taking spindle speeds of 580 RPM and travel speeds of 36, 76, 102, 146, and 216 mm/min into account. The tool angle and dwell duration evaluated in this study were 2o and 20 seconds, respectively. Fabricated samples were then sectioned in accordance with industry standards. Tests to determine factors like as tensile strength, impact load, and microstructures at various temperature zones. The results show that the maximum joint efficiency for a double-side friction stir welded connection at 102 mm/min was 96%.

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