Abstract
Friction stir welding (FSW) has become a popular method for connecting low weight metals. Material joining occurs in the solid state in FSW. Inserting a rotating tool travelling over the faying surfaces of the material to be bonded is used to complete the procedure. It produces practically defect-free welds with little distortion and a fine grain structure. However, the welding mechanism and process parametric combination for welds with consistent and dependable outcomes are not well understood. The thesis details the experimental efforts made to suggest an optimal combination of parameters with simple tool geometry for FSW at greater linear speeds. The materials for research were two precipitation hardenable aluminium alloys: 6mm thick 2219-T87 and 5083H321. The influence of process parameters on weld microstructural changes and defect development was also examined. The optimal combination of process parameters for the FSW of aluminium alloys was proposed, and the most relevant parameter for weld strength and quality was discovered.
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