Abstract
Abstract Friction Stir welding (FSW) is preferred over conventional welding process for dissimilar materials joining. This is due to controlled heat input which restricts the brittle intermetallic compound (IMC) formation. In the present study, aluminum alloy 6061-T6 and magnesium alloy AZ31B were friction stir welded at the tool rotation speed of 545 rpm, feed speed of 31.5 mm/min, 20 tilt angle and 2 mm offset towards Mg alloy (advancing side) with different tool pin diameter and cooling conditions. Compressed air and CO2 cooling conditions were used to control the heat input. Visual inspection, weld interface, tensile and microhardness measurement were carried out. In-process temperature measurement was carried out for different cooling conditions to relate the heat input. It indicated decreased peak temperature on the advancing side with increased cooling severity. With increasing cooling severity, tensile strength increased to 108.94 MPa. However, microhardness decreased with increased cooling severity due to the possibility of reduced Al/Mg IMC formation.
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