Abstract
This paper highlights the influence of load-controlled experiments on heat input and corresponding improvement in mechanical properties of dissimilar friction stir lap welding of aluminum 6061 alloy (Al-6061) and mild steel (MS) with different thicknesses. Dissimilar welds are produced at different loads and heat input conditions. The microstructure and chemical composition of the weld interface were characterized to determine the deformation behaviour, quality of interfacial layer formation, and joining mechanisms at the aluminum-to-steel interface. An improvement (more than 65% joint efficiency) in shear tensile properties was reported under optimized process conditions. Mechanisms associated with improved tensile properties have been identified. Mechanical mixing, the formation of intercalated structures, and the evolution of diffusion layers are considered the mechanisms of dissimilar joint formation.KeywordsDissimilar friction stir weldLoad control experimentsMicrostructureTensile propertiesMechanical mixingMechanismsIntercalated structures
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