Effect of Friction Stir Processing on Mechanical Properties and Wear Resistance of Tungsten Inert Gas Welded Joint of Dissimilar Aluminum Alloys

Abstract

In this work, we examine TIG welded joints processed with friction stir processing at tool rotational speeds (TRSs) of 700, 800, 900, 1000, and 1100 rpm, with a constant feed rate of 70 mm/min and tilt angle of 1°. The percentage improvement in the tensile strength of TIG + FSP (TF) weldments was observed to be 78.57 and 75.89%, compared with TIG welded joints with ER4043 and ER5356 filler, respectively, at a TRS of 1100 rpm. A maximum tensile strength of 196 MPa was observed in a TF welded joint with ER5356 filler, and a minimum tensile strength of 98 MPa was observed in the TIG weldment with ER4043 filler. Cleavage facets, tear ridges, and large dimples were observed in fractured specimens of TIG welded joints, whereas fine, equiaxed dimples were observed in TF welded joints. A maximum micro-hardness of 137 HV in the stir zone was observed in TF welded joints at a TRS of 1100 rpm. TF welded joints with ER5356 filler had superior wear resistance compared to TIG and TF welded joints with ER4043 filler.