Temperature variations during friction stir welding result from the heat generated by the frictional action of a rotating tool on the workpiece. This temperature distribution affects the mechanical behaviour and ultimately the quality of welds produced. The study of the correlations between process parameter, temperature, mechanical properties and microstructure has become imperative in order to promote welds devoid of defects and possessing sound mechanical properties and to establish a temperature feedback control for effective components designs for industrial applications. This work studied the impact of tool rotational speed on temperature profile, mechanical behaviour and microstructure of friction stir welding of dissimilar aluminium alloy 6101-T6 and 7075-T651. Processing parameters of three different rotational speeds with values 1250 rpm, 1550 rpm and 1850 rpm and a constant travel speed of 50 mm/min were employed. The temperature profile was measured with one end of thermocouple wires embedded in the plates and the other end connected to a data capturing software device. The temperature profile indicates that the temperature rises with time and is higher at the retreating sides than at the advancing side of the weld. The tensile test results show that the ultimate tensile strength decreases as the temperature increases. Microstructural observations of weld zone revealed non-uniformity in material flow. However, more material penetration into each other occurred more at 1550 rpm.

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Dissimilar friction stir welding (FSW) between 6101-T6 and 7075-T651 aluminium alloys was conducted. Three different parameters each were investigated for rotational speed and travel speed, and the effects of these parameters on the tensile behaviour, hardness and wear were evaluated. The results indicate that the ultimate tensile strength increases with an increase in the feed rate. However, the increase in rotational speed decreases the ultimate tensile values. The fractured analysis of the tensile samples shows similarities in the fractured pattern as all the samples failed at heat affected zone close to the 6101-T6 alloy. The hardness varies across the heat affected zones and nugget zone both at constant rotational speed and welding speeds. The highest resistance to wear occurred at 65 mm min À1 and 1850 rpm welding speed and rotational speed respectively while better material mixing was achieved at the nugget zone of the welds at 1250 rpm and 110 mm/min. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.2 O.P. Abolusoro and E.T. Akinlabi: Manufacturing Rev. 7, 1 (2020)