Abstract
The effect of velocity ratios on tensile properties and microhardness of dissimilar Aluminum alloys 2024 and 7075 welds fabricated via friction stir welding (FSW) have been analyzed in this current study. Microstructure analysis of the cross-section of the joints revealed distinct lamellar bands and various degrees of intermixing that were correlated with tool rotational speeds. Due to the distinct mechanical properties of the two alloys, microhardness measurements showed a consistent asymmetric hardness distribution profile across the weld nugget, regardless of tool rotational speed. Under monotonic tensile loading, an increase in the joint strength was observed with the increase in the velocity ratio. On the other hand, the failure observed through the heat-affected zone at high rotational speeds was produced due to the material softening as confirmed by the microhardness measurements. The observed tensile properties and hardness are correlated with microstructure and fracture features.
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