Optimization of process parameters in Friction Stir Welding of dissimilar aluminum alloys (AA6061–T6 and AA5052–H32)

Abstract

Friction stir welding (FSW) is a solid-state welding method for the welding of aluminum alloys and has been used in aerospace, railway, automotive and marine applications. Solid-state welding processes solve several problems that occur during fusion welding of Al-alloys like HAZ liquation cracking, porosity, and segregation. Aluminum Alloys of two different series AA 5052 and AA6061 thickness of 6mm are FS welded using process parameters like tool rotational speed (900,1100,1400) rpm, transverse speed (40,50,60) mm/min, and pin profiles (cylindrical, conical, and square). This article aims to optimize the mechanical and metallurgical properties of the above dissimilar combination to evaluate the performance and characteristics of the welded joints. The combined Taguchi and Grey relation analysis experimental method was chosen to construct the number of welding experiments. The plates are successfully welded, and the welded plates are tested at room temperature to examine their tensile strength and hardness. The findings indicate that the square pin profile, the rotational speed of 1400 rpm, and the transverse speed of 40 mm/min are the optimum parameters for joining these dissimilar joints.

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

“…The authors find that the increase in rotational speed leads to poor wear performance, whereas the increase in welding speed shows better wear performance. Heramo and Workneh [148] investigate AA6061-T6/AA5052-H32 dissimilar joints by varying rotational speed (i.e., 900, 1100, and 1400 rpm), transverse speed (i.e., 40, 50, and 60 mm/min), and pin profiles (cylindrical, conical, and square). In particular, the square pin profile, the rotational speed of 1400 rpm, and the transverse speed of 40 mm/min are the optimal parameters.…”