Abstract
Next-generation jet engines for the aerospace industry depends on the manufacturability and improved ability of titanium and aluminium alloys that can withstand high temperatures. The raw materials in form of sheet, plate, billet, ingot, and rod of limited sizes need to be either machined or welded in order to produce the desired structure with optimal buy-to-fly ratio. The friction stir welding (FSW) technique is considered to offer advantages over fusion welding in dissimilar joining but some challenges still exist in the FSW of dissimilar metals. The present research employed a modified butt joint configuration in FSW of Ti6Al4V to Al6061 alloy with a special pin plunge set up, aiming to obtain a high-quality Al-Ti joint by avoiding butt flaw and reducing the tool shoulder attrition. This work briefs about the microstructure of the obtained sound joint in terms of optical Microscopy, Scanned Electron Microscopy, and Electron Backscattered Diffraction techniques.
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