Abstract
In this study, dissimilar friction stir welding of mild steel and A7075 aluminum alloy was conducted at a constant tool rotational speed (900 rpm) and different welding speeds of 100–400 mm/min with an interval of 100 mm/min. A thermocouple was employed to record the thermal cycle and the maximum reached temperatures of the A7075/steel interface during the joining process. The higher the welding speed, the lower the maximum temperature recorded during the joining process. Conducting the joining process at a high welding speed also enhanced the cooling rate and, thus, effectively contributed towards eliminating the thermal residual stresses and suppressing the interfacial intermetallic compounds growth. As a result, 100% joint efficiency with a steel base metal fracture was obtained for the joints fabricated at the welding speeds of 300 and 400 mm/min.
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