Abstract
Dissimilar materials of 5052-O and 6061-T6 aluminum alloys are friction stir welded by arranging the material location and under various welding conditions. The metal flow phenomenon in friction stir welding comprises two modes of metal transfer. The first mode of metal transfer takes place layer by layer and it is caused by the shearing action of the tool shoulder, while the second mode is caused by the extrusion of the plasticized metal around the pin. The aim of the present study is to understand the metal flow by interchanging the base materials arrangement, namely advancing side and retreating side and its effect on mechanical properties. An image processing technique is used to determine the quantitative amount of the first mode. Effect of first mode of metal transfer on ultimate tensile strength and yield strength have been analyzed. This analysis shows that the first mode of metal transfer increases with increasing travel speed and reveals a substantial relationship between the mechanical properties and the first mode of metal transfer. Material mixing of the joints has been evaluated by using optical microstructure, scanning electron microscopy and energy-dispersive spectroscopy. Results of this analysis show that better material mixing and consequently improved mechanical properties are achieved when 5052 is placed on the advancing side.
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