Abstract
The aim of this investigation was to study the effect of tool pin geometry and pass number on mechanical and microstructural behaviour of SiC-incorporated dissimilar friction stir welding of 6-mm-thick plates of AA6061-T6 and AA2024-T351. Two tool pin geometries, square and triangle frustum, were used. It was found that the weld made by square frustum pin and two passes with rotation in the same direction produces more homogenized and finer distribution of SiC particles. Also, the grain size of stir zone in the weld made by two passes is finer than that made by one pass. The weld made by triangle frustum pin shows higher thermo-mechanically affected zone hardness, natural aging kinetics and tensile strength than the others.
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