Abstract
Aluminium alloys have gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to weight ratio and good corrosion resistance. Compared to the fusion welding processes that are routinely used for joining structural aluminium alloys, friction stir welding (FSW) process is an emerging solid state joining process was invented in 1991 by TWI, in which the material that is being welded does not melt and recast. The dissimilar friction stir weldability of 7075-T651 and 6061-T651 aluminium alloys was investigated in this study with various process parameters like tool rotational speed, tool welding speed and tool pin profiles. The macro and microstructure, scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS) were conducted to study the effects of rotational and welding speeds with the pin profiles for dissimilar friction stir welded butt joints keeping AA6061-T651 plate on the advancing side. The good mixing of both the materials joined was obtained at lower welding and higher rotational speed.
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