Abstract
Dissimilar aluminum butt joints were successfully joined using a friction stir welding machine, employing four welding speeds (50, 60, 70, 80 mm/min), four rotational speeds (900, 1000, 1100, 1200 rpm), and four different weld tool profiles (T1=12/4, T2=15/5, T3=16/4, T4=20/5 in D/d ratio). The corrosion analysis suggests that specimens 9, 10, 11, and 13 exhibit higher corrosion resistance, with a breaking potential of -0.6 eV, while specimen 8 shows the lowest corrosion resistance with a breaking potential of -2.1 eV. The results from the differential scanning calorimeter illustrate the formation of precipitation dissolution due to high heat generation at the nugget zone. An eddy current defect detector experiment was conducted to detect surface flaws in the welded samples. Few surface cracks were observed in the T2 profile specimens, which have a larger contact region or shoulder diameter, while more surface cracks were observed in the T1 profile samples.
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