Increase In Rotational Speed Research Articles

Study on Thermal Characteristics of Angular Contact Ball Bearings Considering Roundness Error

To develop an angular contact ball bearing with low power consumption, a heat generation calculation model for angular contact ball bearings has been established based on bearing quasi dynamics, elastohydrodynamic lubrication theory, heat transfer theory, and Kirchhoff’s law of energy conservation, considering the effects of roundness error, bearing preload, centrifugal effect, and thermal expansion. The correctness of the model is verified through experiments. The influence of different operating conditions and roundness errors on the thermal characteristics of angular contact ball bearings is analyzed. The results of the calculation indicate that when the roundness error order is equal to the number of balls n/2 ± 2 (where n = 1, 2, 3, …), the overall heat generation of the bearing is lower than that without considering the roundness error. When the roundness error order is equal to (2n − 1)/4 ± 2 (where n = 1, 2, 3, …), the overall heat generation of the bearing is higher than that without considering the roundness error. At the same rotating speed, the overall heat generation fluctuates as the roundness error order changes, and the trend becomes more pronounced as the rotating speed increases. The maximum overall heat generation is achieved when the roundness error order equals (2n − 1)/4 times (where n = 1, 2, 3, …) the number of balls. When the roundness error order is equal to n/2 times the number of balls (where n = 1, 2, 3, …), the bearing’s overall heat generation is minimal. The variation in the total heat generated by the bearing is directly proportional to the amplitude of the roundness error. With the increase in roundness error harmonic order, the bearing integral heat generation shows a periodic change, and the change period has a mapping relationship with the number of balls.

Numerical Investigation of Supercooled Large Droplets Impingement Characteristics of the Rotating Spinner

Aircraft engine icing caused by supercooled large droplets (SLD) poses a significant threat to flight safety. In this paper, the SLD impingement characteristics of the rotating spinner were investigated using FLUENT UDS and the governing equations for water droplet motion were solved based on the Eulerian method. The droplet breakup was simulated using the number density equation, while the droplet rebound and splashing were simulated using a semiempirical model. The effects of rotational speed, droplet diameter, and inflow velocity on the SLD impingement characteristics of the rotating spinner were studied. Some new valuable insights have been found for the SLD impingement. The results indicated that as the rotational speed increases, the local collection efficiency of the rotating spinner decreases. Higher rotational speed results in reduced droplet impingement angle and stronger droplet rebound and splashing. For the droplets with diameters smaller than 111 μm, the local collection efficiency increases with the increase of the droplet diameter. However, when the droplet diameter exceeds 111 μm, the local collection efficiency decreases near the leading edge of the rotating spinner. Additionally, the local collection efficiency decreases as the inflow velocity increases near the leading edge of the rotating spinner. However, higher inflow velocities lead to larger droplet impingement angles, resulting in higher local collection efficiency near the tail of the rotating spinner. The critical impingement angle increases with the increase of the inflow velocity, leading to a more pronounced rebound and splashing of SLD. The research in this paper provides useful help for ice shape prediction and anti-icing system design of rotating spinner in SLD environment.

Investigations on the performance of a novel hybrid twisted tapered, three-bladed horizontal axis small wind turbine

Small wind turbines could bring a lot of difference in providing power to remote and inaccessible locations. These turbines could be mounted on rooftops as standalone units or hybrid units. One of the factors deciding the magnitude of power generation in wind turbines is the rotational speed of the blades. A proper blade selection and orientation could make a lot of difference in such a scenario. This work is focused on a novel hybrid twisted tapered three-bladed wind turbine made of NACA4412 and E193 blade profiles, for better aerodynamic performance and high structural stability. A simple tapered three-bladed turbine (STBT) was considered for performance comparison using testing parameters like tip speed ratio, coefficient of performance, actual power generated at wind velocities (2 m/s to 8 m/s) and pitch angles (0, ± 2o, and ± 10o). The results indicate that the hybrid twisted-bladed turbine (HTBT) generated 1.52 times more power at −10oAoA, and 1.11 times more power at −2oAoA; the increase in power between 42.5% to 121.5%, the increase in rotor speed from 30.5% to 94.4%, over the simple tapered blade-mounted turbine. However, the simple tapered blade profiled wind turbine performed better without altering the blade pitch angle.

Experimental investigation into segregation behavior of spherical/non-spherical granular mixtures in a thin rotating drum

This paper uses physical experiments to investigate the segregation behavior of binary granular mixtures in a quasi-two-dimensional rotating drum. Spherical polyformaldehyde (POM) beads and cylindrical red beans constitute the granular mixtures. The effects of particle size, particle density, and particle shape interplay during the segregation process in the spherical/non-spherical particulate system. A long-axis ratio (LAR), the ratio of the spherical POM beads' diameter to the red beans' primary dimension, was defined to explore the particle shape effect. The experimental results show that the long-axis ratio and the rotation speed play substantial roles in the granular segregation behavior. As the long-axis ratio increases, the steady-state segregation intensity decreases. An increase in the rotation speed enhances the segregation of the binary granular mixtures for each long-axis ratio studied here. In addition, the average velocity and granular temperature of spherical POM beads increase as the long-axis ratio increases. Both properties also increase as the rotation speed increases. The dynamic angle of repose for the binary mixtures increases with the increase in the long-axis ratio. Most interestingly, reverse granular segregation does occur at a long-axis ratio of 0.70 with the cylindrical red beans in the core and the spherical POM beads at the periphery for each rotation speed studied here. This reverse segregation has not been observed in previous studies. This highlights the substantial impact of particle shape on the granular segregation in binary granular mixtures.

Five-DOF nonlinear tribo-dynamic analysis for coupled bearings during start-up

The novelty of this study lies in its investigation of the transient coupling relationship between 5-Degrees-Of-Freedom (5-DOF) nonlinear dynamics and mixed lubrication behaviors of a Coupled Journal and Thrust Water-Lubricated Bearing (CJTWLB) used in rim-driven propeller during start-up. A fully coupled tribo-dynamic model is established, in which 5-DOF nonlinear dynamic behaviors interact with the mixed lubrication performance. The model incorporates nonlinear external excitations, including realistic forces and moments generated by the propeller during start-up. The present numerical model is validated using available experimental and theoretical results from existing literature. Through numerical simulation, the transient nonlinear dynamic and mixed lubrication behaviors of the CJTWLB during start-up are revealed. Results indicate that the evolution of elastic-plastic contact behaviors with acceleration time differs from that of a single journal or thrust bearing. The exciting moments, especially for the moment along the x-axis, and common boundary condition are identified as crucial factors affecting the nonlinear tribo-dynamic performances during start-up in such bearings. Additionally, an interesting finding is that an increase in rotational speed hardly improves the transient mixed lubrication performance of the journal bearing part of the CJTWLB during start-up. Finally, the results demonstrate that a higher blade number is beneficial for improving the stability of the CJTWLB.

Numerical study on the heat transfer performance evaluation, flow characteristics, exergy efficiency, and entropy generation analysis of a novel coaxial geothermal heat exchanger

In order to improve the geothermal heating capacity of buildings, this paper proposes a coaxial geothermal heat exchanger (CGHE) with an inner tube assembled with continuous spiral fins (CSF). The thermal performance and flow characteristics of a CGHE with inner tubes assembled with different widths of CSF were numerically investigated at different rotational directions and rotational speeds (rpm = −30, −60, −90, −120, 30, 60, 90 and 120). The heat transfer mechanism in different rotational directions and rotational speeds was revealed and the heat transfer performance 、exergy efficiency and entropy generation were analyzed. The results of the study showed that the assembly of different width CSF on the inner tube of the CGHE exhibited completely different thermal performance and flow characteristics in the case of clockwise and counterclockwise rotation. Nu decreases in clockwise rotation and increases in counterclockwise rotation, but with small changes. The f of each H is always greater than the static f when rotating clockwise, and each width f increases as the clockwise rotation speed increases. And the f of each H in counterclockwise rotation is opposite to that in clockwise rotation. The PEC of each H decreases as the clockwise rotation speed increases and increases as the counterclockwise rotation speed increases, with a maximum PEC = 1.813 for H = 11 mm and rpm = 120. And counterclockwise rotation can improve the exergy efficiency of CGHE. The entropy generation rate is significantly higher than that of smooth tubes when Re exceeds 12,639.

Experimental study on the melting heat transfer characteristics of a phase change material under mechanical agitation

Phase change materials (PCMs) are extensively employed for the thermal management of electronic devices, but their low thermal conductivity often results in slow heat absorption and release in practical applications. Existing improvement measures primarily focus on enhancing heat conduction, while research from the perspective of convection is scarce. Therefore, an experimental study on the melting heat transfer characteristics of n-docosane under mechanical agitation (0–1600 RPM) was conducted at 4.7–34 kW/m2. Upon agitation, the heating wall temperature (Tw) rapidly decreases, while the PCM temperature, heat transfer coefficient and Nusselt number significantly increase, and their variation amplitude is positively correlated with the rotation speed. This can be attributed to enhanced liquid PCM convection and accelerated solid PCM melting. At 8.5 kW/m2, the Tw at 1600 RPM is approximately 27 °C lower than that at 0 RPM, leading to a fourfold increase in the Nusselt number. Tw decreases with increasing rotation diameter, especially at lower rotation speeds. From 30 to 50 mm, the temperature decreases by approximately 13 and 10 °C at 800 and 1600 RPM, respectively. Tw changes slightly with increasing rotation height. Agitation can reduce the increase in Tw caused by a higher heat flux. Agitation can quadruple the upper limit of heat flux from 8.5 to 34 kW/m2 while maintaining consistent thermal control requirements. The power consumption of agitation increases as the rotation speed and diameter increase, peaking at 10.1 W. Moreover, after considering the minimum start-up time, Tw, and power consumption, the optimal configuration is determined: a rotation height of 10 mm and a rotation diameter of 40 mm for 1600 RPM and 50 mm for 800 RPM. These findings hold significant implications for PCM-based thermal management, particularly in terms of incorporating active convection enhancement.

Experimental and numerical evaluation for drum dynamic reliability under extremely complex working conditions

Coal mining machine drums are prone to damage and malfunction under extremely complex working conditions, which seriously affects the efficiency and safety of coal production. In this paper, based on the theory of coal rock cutting and virtual simulation technology, finite element models of drum cutting coal rock were established and then verified by physical experiments. Through simulation analysis, the dynamic reliability of the drum was studied from three aspects: load, stress and wear, and a mathematical model of drum load was established with respect to the traction speed and drum rotation speed; based on the orthogonal test, the optimal working parameters to improve the wear resistance of the drum were derived. The results of the study found that when the traction speed increases, the load on the drum increases, and when the drum rotation speed increases, the load on the drum decreases; when the traction speed is increased from 2 to 6 m/min, the stress on the pick body under different rotation speeds increases to different degrees, with an average increase rate of 27.394%; when the drum rotation speed is 90 r/min, the traction speed is 3 m/min, and the coal loading mode is projectile loading, the wear depth of the picks and spiral blades is relatively small. The research method and results of this paper can provide a reference for the selection of the drum working parameters.

Insights into the effect of susceptor rotational speed in CVD reactor on the quality of 4H-SiC epitaxial layer on homogeneous substrates

In this work, 4H-SiC homoepitaxial layers were grown on 4°off-axis substrates at different susceptor rotation speeds by using a hot-wall horizontal CVD reactor. The effect of different susceptor rotation speed on the quality of 4H-SiC epitaxial layers in terms of thickness, thickness uniformity, crystallinity, surface morphology and morphological defects was investigated via Fourier transform infrared spectroscopy (FTIR), high-resolution X-ray diffraction (XRD), atomic force microscopy (AFM), confocal differential interference contrast microscopy (CDIC), ultra-violet photo-luminescence spectroscopy (UV-PL), scanning electron microscopy (SEM), and micro-Raman spectroscopy, respectively. A flow field simulation was performed to explain the impact of susceptor rotation speed on the film deposition. The FTIR results suggested that the susceptor rotation speed could be an important factor to adjust thickness uniformity and deposition rate. The XRD patterns showed that crystallinity was independent of the susceptor rotation speed. The surface morphology can be improved by changing the susceptor rotation speed. According to CDIC scans, the down-fall related defects were reduced through the increase in the susceptor rotation speed. The origin of down-fall related defects was interpreted by Raman spectroscopy and speculative models. To sum up, the susceptor rotation speed is a crucial factor in increasing growth rate and improving uniformity. Also, the faster susceptor rotation speed helps reduce the number of down-fall related defects in the hot-wall CVD reactor.

Effects of Friction Stir Processing on the Microstructure and Mechanical Properties of an Ultralight Mg-Li Alloy

Magnesium–lithium alloys are arguably the lightest metal structural materials but have low strength. In order to increase strength, friction stir processing (FSP) is applied to a hot-rolled Mg-10Li-3Al-3Zn (LA103Z) sheet to study the effects on the microstructure and mechanical properties. In this study, the strengthening mechanisms of various FSP regions of an Mg-Li alloy were clarified by a combination of numerical simulation and experimental method. Based on ANSYS APDL, a finite element model with a moving heat source is established. Rotational speeds of 800, 1000, and 1200 rpm and traverse speeds of 100, 110, and 120 mm/min were used in this research. The simulation results confirm that the influence of the rotation speed on the alloy temperature field is greater than that of the travel speed. The temperature of the processing area increases with an increase in rotation speed and decreases with an increase in travel speed. Then, hot-rolled LA103Z alloy plates are processed by FSP. The correspondence between the numerical simulation and experiment was verified by infrared thermography. The results indicate that FSP decreases the grain size significantly for the dynamic recrystallization and dramatic mechanical crushing of the stirring pin. The α-Mg and AlLi are solid soluted in the β-Li matrix. The tensile strength of the processing zone is 260.67 MPa (1000 rpm, 110 mm/min) versus the 170.47 MPa of the base metal. The SZ has the highest microhardness of 77.8 HV (800 rpm, 120 mm/min) and decreases gradually to the BM. The severe deformation, recrystallization, and solid solution of the α-Mg are important factors contributing to the improved mechanical properties.

STUDY ON VIBRATION AND TEMPERATURE RISE CHARACTERISTICS OF FULL CERAMIC BALL BEARINGS UNDER HIGH-TEMPERATURE CONDITIONS

In order to study the vibration and temperature rise characteristics of full ceramic ball bearings under high-temperature conditions, the bearing vibration test of a simulated high-temperature environment was conducted in this paper. The vibration and temperature rise properties of full ceramic ball bearings were measured under high-temperature variable working conditions in this experiment. The results demonstrate that the temperature rise and vibration acceleration of full ceramic ball bearings increase with the cavity temperature increasing from 50°C under a single load. The vibration and temperature rise increased with an increase in rotational speed. Due to the mechanical characteristics of a silicon nitride material, the change of temperature rise of a full ceramic ball bearing is relatively small. When temperature and speed were stable or only very low, full ceramic ball bearings operated stably. The results of the experiment can serve as a guide for the operational state of full ceramic ball bearings in high-temperature environments.

SPECIFICS OF THE COMBINED ELECTROMAGNETIC AND THERMAL PRE-TREATMENT OF THE COAL-WATER FUEL

An increase in fuel usage efficiency is the path to eliminate environmental impact, decrease greenhouse gas emissions, and prevent climate warming. Coal-water fuel (CWF) is seen as a replacement for coal and heavy oil in some applications but it has a number of disadvantages that must be addressed before it can be gasified or burned. Pretreatment (or activation) is one of the methods for improving the fuels. Since CWF is an electrically conductive substance, the electromagnetic field can be used for various types of influences: heating, stirring by rotation, etc. Numerical research was carried out to study the possibility of simultaneous heating and movement of CWF by a rotating electromagnetic field created in the stator of an asynchronous electric motor. The correlations between the required electromagnetic field parameters and tangential velocity profile were investigated. It was found that a change in the position of the maximum tangential velocity with increasing rotation speed can lead to a decrease in magnetic reluctance and, consequently, to a decrease in the active power required to rotate the CWF.

Research of crushing sunflower stalks when mowing with a cutting device with a vertical axis of rotation

Annotation Purpose. The purpose is to increase the efficiency of the process of cutting sunflower stalks with a cutting device with a vertical axis of rotation for harvesting for energy purposes. Methods. The methods of scientific planning of experiments and regression analysis were used to search for optimal conditions. Modeling and statistical processing of the results was performed using a personal computer and mathematical software products with the help of computer program packages: Microsoft Excel and StatSoft Statistica. Results. The results of research on the process of cutting sunflower stalks with a cutting device with a vertical axis of rotation for harvesting for energy purposes are presented. The dependence of the influence of the angular speed of rotation of the knives and the height of the folding blade of the knives on the degree of crushing of sunflower stalks by a cutting device with a vertical axis of rotation was obtained. Conclusions. It was established that the angular speed of rotation of the knives of the cutting machine has a decisive influence on the degree of grinding of sunflower stalks. With an increase in the angular speed of rotation of the knives from 105 s-1 to 185 s-1, the content in the mown mass of sunflower stalks over 100 mm in size decreases from 68–69 % to 39–51 % at the various modes in which the research was conducted. A significant influence of the height of the folding blade of the knives on the degree of grinding of sunflower stems was noted when the angular speed of rotation of the knives was increased to 145–185 s-1. Thus, with a significant angular speed of rotation of the knives of 185 s-1 and an increase in the height of the blade from 20 mm to 32 mm, a decrease in the content of sunflower stems over 100 mm in the mown stem mass was established from 51 % to 39 %. Keywords: sunflower stalks, mowing, grinding, cutting device, knives, shovels.

Numerical Simulation Analysis and Experimental Verification of Pressure-resistant Self-compensating Oil Seal

The glyd ring of the transmission device is prone to wear and leakage, which causes the sealing failure to cause the failure of the transmission device. Therefore, a pressure-resistant self-compensating oil seal is proposed in this research. The influence of working conditions such as pressure and rotational speed on its temperature is studied by the numerical simulation method. An experiment bench for oil seals is constructed and utilized to validate the simulation findings. The above research results can ensure the safe and stable operation of the transmission device seal for a long period. In this research, the effect of working conditions such as pressure and rotational speed on its temperature of the glyd ring and the pressure-resistant self-compensating oil seal is compared, and it is verified by the experiment results. The research results show that with the increase of pressure and rotational speed, the temperature of the two seals also increases. Under the same condition, the temperature of the pressure-resistant self-compensating oil seal is significantly lower than that of the glyd ring. The temperature rise of the pressure-resistant self-compensating oil seal can be reduced by about 27 % compared with the glyd ring.

Performance Analysis of Stirling Engine Type Alpha Using Thermodynamic Approach Based on Schmidt Theory

Environmental concern and the impact on climate change have spawned various technological innovations for high efficiency engines that save fuel and produce less carbon emissions. Technological innovations that operate on a closed cycle can use variety of heat sources, produce no emissions and very high efficiency was Stirling engine. This research aims to design a Stirling engine type Alpha with a capacity of 228 cc with a phase angle of 90 degrees, then analyze its performance in the form of power indicators and thermal efficiency indicators and determine the effect of the increase in temperature difference between the compression chamber temperature and the expansion chamber temperature towards engine rotation speed. The method used to analyze engine performance is the Schmidt method, which is a Stirling engine performance analysis method based on isothermal expansion and ideal gas compression. The result of this research is that the Stirling engine which is designed starts working when the compression chamber temperature is 31.9 degrees Celsius and the expansion chamber temperature is 482.2 degrees Celsius. The highest engine speed is 598 rpm which is obtained at a compression chamber temperature of 45.5 degrees Celsius and an expansion chamber temperature of 662.4 degrees Celsius. The engine power indicator is 194.6 watt at 598 rpm, while the thermal efficiency indicator is 65.94 percent. Based on the experimental data, it is also known that the increase in temperature difference between the compression chamber temperature and the expansion chamber temperature causes an increase in engine rotation speed.

Experimental Study on Performance of a Hydraulic Francis Turbine with Variations of Runner Speed

This investigation was carried out to evaluate the characteristics of a Francis water turbine. Several variations of inlet valve openings of the turbine were tested to determine the effects of changes in rotational speed of runner on turbine performance. The method used in this study was experimental measurement using a test rig installation in Diponegoro University. The results found that discharge was not change significantly with increasing speed. The torque decreases as the turbine rotational speed increases. The break horse power (BHP) and efficiency curves are nearly identical. Both BHP and efficiency increase when speed are increased until the maximum condition is reached, then from this maximum condition, as speed increase, the BHP and efficiency gradually decrease.

Analysis of Polyurethane Foam Machining Parameter Influence: Current Status and Perspective

Nowadays, polyurethane (PU) foam has successfully replaced various engineering materials in many applications due to its many advantages in mechanical and thermal properties. In various applications, PU foam must be formed into various 3-dimensional models according to user requirements by utilizing CAM software and CNC milling machining to manufacture a product. Thus, the selection of cutting parameters in the milling machining process in terms of the nature and character of the material and cutting tools is essential and significantly influences the geometric structure and surface roughness of the PU foam products produced. Based on the review of this article, several machining parameters must be appropriately considered, including spindle rotation speed, depth of cut, cutting tool selection, and feed rate. Vibration will increase as the spindle rotation speed increases, which brings cutting tools but results in better surface quality. Continuous chip formation can be achieved by selecting the proper cut depth and producing low surface roughness values. Selecting suitable cutting tools and geometries that match the material characteristics can reduce the risk of material damage during the machining process, thereby reducing the surface roughness value. Finally, a low cutting rate will minimize surface roughness but increase the risk of cutting-edge wear.

Vortex fluidic regulated phospholipid equilibria involving liposomes down to sub-micelle size assemblies.

Conventional channel-based microfluidic platforms have gained prominence in controlling the bottom-up formation of phospholipid based nanostructures including liposomes. However, there are challenges in the production of liposomes from rapidly scalable processes. These have been overcome using a vortex fluidic device (VFD), which is a thin film microfluidic platform rather than channel-based, affording ∼110 nm diameter liposomes. The high yielding and high throughput continuous flow process has a 45° tilted rapidly rotating glass tube with an inner hydrophobic surface. Processing is also possible in the confined mode of operation which is effective for labelling pre-VFD-prepared liposomes with fluorophore tags for subsequent mechanistic studies on the fate of liposomes under shear stress in the VFD. In situ small-angle neutron scattering (SANS) established the co-existence of liposomes ∼110 nm with small rafts, micelles, distorted micelles, or sub-micelle size assemblies of phospholipid, for increasing rotation speeds. The equilibria between these smaller entities and ∼110 nm liposomes for a specific rotational speed of the tube is consistent with the spatial arrangement and dimensionality of topological fluid flow regimes in the VFD. The prevalence for the formation of ∼110 nm diameter liposomes establishes that this is typically the most stable structure from the bottom-up self-assembly of the phospholipid and is in accord with dimensions of exosomes.

EXPERIMENTAL STUDY OF THE PRESSURE DROP AND FLOODING IN A ROTATING PACKED BED REACTOR

In conventional packed beds, mass transfer and flooding limitations lower the productivity of many processes. The almost zero sensitivity to variations in gravitational force has made centrifugal processes to have great potential for enhancing heterogeneous catalytic reactions. We studied a rotating packed bed (RPB) reactor as a gas/liquid contactor for multi-phase catalytic reactions. The scarcity of fundamental data on the hydrodynamics and mass transfer of the reactor limits the design, scale-up, and retrofitting of RPB reactors. Hence, we focused on the hydrodynamic behavior of the device. Previous studies on RPB reactor flooding and operating limits dwelled on visual observations and pressure drop variations only. However, physical visualizations are subjective because RPB reactor pressure drop variations are too inconsistent to be used to determine the upper operating limit during their operations. A robust quantitative method of obtaining RPB reactor flooding limits based on the flow rate of the ejected liquid, supported by visual observation and pressure drop measurement, was presented. The aim was to identify, with greater certainty, RPB reactor hydrodynamic characteristics and provide a more standard method of identifying it. The average increase in single-phase pressure drop per unit increase in rotation speed in the range investigated was 0.75Pa/rpm, and the average increase in pressure drop per unit increase in gas flow rate was 4.11Pa/Nm3h-1 within the operating range investigated.

The study investigates the effects of tool pin length, rotation speed, and dwell time on the microstructure and tensile strength of dissimilar joints between low-carbon galvanized steel and aluminium T6-6061 through friction stir spot welding

Friction stir welding is an efficient method for joining steel and aluminum plates at a point of disturbance. In many studies, the tool is only introduced into the aluminum plate, avoiding penetration into the steel plate due to its high strength and the need for a robust tool. Under such conditions, the created connection usually possesses low mechanical properties. In this research, by increasing the strength of the H13 steel tool through thermal operations, the possibility of penetration and bonding of aluminum 6061 with galvanized low-carbon steel has been provided. Moreover, by penetrating the steel plate, the integration of galvanized layers in the disturbance region has been facilitated. The examined variable parameters include pin length, rotational speed, and tool dwell time. Mechanical properties such as tensile strength, fracture force, and Vickers hardness were investigated. Furthermore, the weld microstructure and intermetallic layers were examined using scanning electron microscopy (SEM) and EDS analysis. Tensile and shear strength increase with an increase in pin length, rotational speed, and tool dwell time. Shear fracture loading showed a decrease with increasing pin length, then reached its maximum value when using long pins, while continuously increased with higher rotational speed and longer tool dwell time. As we approach the center of the weld in both the steel and aluminum parts, smaller grain sizes are observed due to increased plastic deformation, more material mixing, and increased mechanical tool pressure, while in the heat-affected zone, a coarse grain structure forms. Hardness in the aluminum plate decreased in the heat-affected zone and reached its minimum value in the thermo-mechanical-affected zone, then increased to the maximum value in the nugget zone, while hardness changes in the steel plate were uncertain. The most influential parameter on mechanical and microstructural properties was pin length, followed by rotational speed and tool dwell time.