Abstract
Friction stir welding is solid-state joining technique widely used in automobile, aerospace, and ship building sectors for welding similar and dissimilar metals and alloys without expending huge amount of energy. The welded joints have relatively good strength, corrosion/wear characteristics as well as fine microstructure leading to limited defects. Friction stir welding was basically started for joining soft metals and alloys. Aluminum and its alloys have wide use in industrial sectors due to their light weight and good strength. Friction stir welding is also intended for joining of aluminum with low melting point metals like copper, zinc, and magnesium sheets. Unlike fusion welding schemes, here the frictional heat between the tool and weld materials does not create the temperatures to melting points; rather, it plasticizes the region temporarily and solidifies the mixture at the joint interface. This work deals with the sustainable friction stir welding of aluminum alloys of variable compositions. The influence of cutting parameters and tool geometry on the mechanical characteristics of joint is discussed. Tensile strength and impact resistance of welded portions are obtained. Theoretical energy required in each case along with other data is estimated for all experimental cases.
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