Abstract
In this work, similar and dissimilar friction stir welds of AA2024 and AA7039 were formed using optimized process parameters and truncated threaded tool. Characterization of weld joints for mechanical and microstructural properties was performed by tensile test, micro hardness test, optical microscopy, scanning electron microscopy, and energy dispersive spectrometry. The tensile strength of similar joints was higher than dissimilar joints despite lower microhardness of former. Fracture of FSW joints was found to be started by the fracture of strengthening precipitate θ or η or both in the region of tensile fracture. Dissimilar joints and similar joints of AA7039 exhibited ductile fracture mode while similar joints of AA2024 showed brittle fracture mode.
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