Abstract
The aim of this work is to study the possibility of joining two plates from aluminum alloys, AA2024-T3 with AA6061-T6, using friction stir welding (FSW) technique. In this study, the plates were prepared by cutting with dimensions (100 x 50 x 5) mm by CNC milling machine with cutting speed of 1200 rpm and variable feeding speed of (25, 30, 35 & 40 mm/min). The FSW was operated by a vertical milling machine at a rotary speed of 930 rpm and linear welding speed of 30 mm/min to obtain welding joints of dissimilar plates. Microstructure, surface roughness and micro-hardness were examined. Corrosion test was also carried out by electrochemical methods for all specimens in 3.5wt % NaCl solution, and the corrosion rate was calculated by Tafel extrapolation method. The obtained results demonstrated that the feeding speed has a significant effect in decreasing the corrosion rate comparing with the base metal due to the plastic deformation that occurs at high feed speed. The decrease in surface roughness provided more connected between the two contact surfaces that contributed in the refinement of the microstructure. The sample welded at feed speed 40 mm/min offered the optimum results.
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