Abstract
The present study investigated the influence of tool rotational speed on dissimilar joints between AA2024-T3 and SS304 metals using friction stir welding (FSW). Optimal results were achieved at 560 rpm tool rotation, 25 mm/min traverse speed, and 1 mm tool pin offset. This rotation rate facilitated proper heat input, inducing plastic deformation and material flow, resulting in an ultrafine grain structure in the stir zone (SZ). 3D profilometry showed variable surface roughness affected by process parameters. Potentiodynamic tests demonstrated improved corrosion resistance in FSWed samples compared to the base material. Vickers hardness testing revealed increased hardness in the SZ due to grain refinement. Wear behavior evaluation highlighted the significant influence of tool rotation on enhancing wear resistance in welded specimens.
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