Abstract
Friction stir welding (FSW) is a solid-state joining technique. One of the major areas where FSW finds a key role in applications is aerospace and automobile sector. FSW is not a defect free welding process. FSW weldments might have surface defects if the combination of welding parameters like tool rotational speed, weld speed, axial load and tool tilt angle does not provide an adequate amount of heat. In this study, a new concept has been developed by combining two tool pin profiles into a one as a hybrid tool pin. A visual inspection has been carried out on dissimilar aluminum alloy AA6082-AA5083 weldments produced by using the triangular tool pin and hybrid tool pin profiles. Surface defects like flash, lack of fill, fin-like flash and burrs were observed on the weldments.
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