Abstract
Solidification is one of the major issues that was faced during the fusion welding of dissimilar non-heat treatable and heat treatable aluminium alloys. To overcome this issue Friction Stir Welding played a very vital role, since it is a solid state welding process. In the current study, dissimilar friction stir welding was carried out between non heat-treatable aluminium alloy AA5083-H111 and heat-treatable aluminium alloy AA6061-T6. The microstructural analysis and the mechanical properties of the dissimilar friction stir welded aluminium alloy AA5083-H111 and AA6061-T6 have been investigated. Both optical microscopy and scanning electron microscopy was used to evaluate the microstructural features. The elemental analysis was carried out using SEM-EDX. The tensile properties are studied using Universal Testing Machine. Hardness at various zones of the welded joints was measured using Vicker’s Hardness Testing Machine. The mechanical properties of the friction stir welded joints were correlated with the microstructure of the dissimilar welded joints.
Highlights
Fusion welding of dissimilar aluminium alloys produces solidification cracking in the weld zone
The microstructure of AA5083-H111 base metal is shown in Fig. 1, a and the microstructure of AA6061-T6 base metal is shown in Fig. 1, b
Some Mg2Si precipitates are in round shape, whereas few precipitates are found to be elongated along the rolling direction of the plate
Summary
Fusion welding of dissimilar aluminium alloys produces solidification cracking in the weld zone. This can be avoided by careful selection of filler material mostly based on the material composition. There is no filler material available for the joining of dissimilar grade of aluminium alloys. Industries recommend solid state welding process as suitable joining method for joining dissimilar grade of aluminium alloys [1,2,3,4,5]. Friction stir welding is used to effectively join any combination of two dissimilar metals [10,11,12,13,14,15]. FSW combines material plastic strain and heat flow [16]
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