Abstract
This manuscript deals with the dissimilar friction stir welding of 2024 and 7039 aluminum alloys, which are mainly used in aviation and automotive industry. A threaded truncated conical tool was used to carry out friction stir welding of dissimilar alloys. The weld joints were characterized by visual inspection, optical and scanning electron microscopy, energy dispersive spectrometry, x-ray diffraction and tensile tests. Weld joints exhibited mixed structure comprising of both the base materials and heterogeneously distributed Cu and Zn in the weld region. The weld strength efficiency was found higher than the elongation efficiency. The low weight percentage of Cu and Zn in weld nugget zone can be attributed to dissolution of strengthening precipitates in this zone. Softening due to dissolution resulted in reduction of mechanical properties of dissimilar welds. The results suggest that 2024 and 7039 dissimilar alloys are friction stir weldable with promising properties.
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