Effect of FSW process parameters on mechanical properties and microstructure of dissimilar welded joints of AA2024 and AA6082

The aluminum alloys AA2024 and AA6082 are the most common alloys used in the storage tank, pipelines, maritime frames, automobile and aerospace industries due to their high corrosion resistance and toughness. In the present work, these dissimilar aluminum alloys were successfully fabricated via friction stir welding (FSW) by varying input parameters (rotational tool speed (TRS) and welding speed). The great mixing of AA2024 and AA6082 was observed at a high rotational speed. The higher TRS enhanced the mechanical properties of the stir zone (SZ). The maximum ultimate tensile strength (UTS) of dissimilar alloys was observed 218.1 MPa at TRS of 1400 rpm with a welding speed of 30 mm/min caused by strain-free fine grains during the dynamic recrystallization (DRX) mechanism. The maximum hardness (93 HV) at SZ was observed at a TRS of 1200 rpm with a 30 mm/min welding speed. The fractured FSWed region at 1200 rpm shows the big and deep dimples, while equiaxed, fine dimples were observed at TRS of 1400 rpm. Copyright (c) 2021 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances

Automated summary

In this study, the dissimilar aluminum alloys AA2024 and AA6082 were successfully fabricated via friction stir welding (FSW) with varying input parameters. The results showed that a high rotational speed led to a great mixing of the alloys, and a higher rotational speed enhanced the mechanical properties of the stir zone (SZ). The maximum ultimate tensile strength (UTS) was achieved at a rotational speed of 1400 rpm with a welding speed of 30 mm/min, attributed to strain-free fine grains during dynamic recrystallization (DRX) mechanism.