Effect of the Process Parameters of Friction Stir Welding of Dissimilar Aluminium Alloys Al 6061-T6 and Al 7075-T6 on the Weld Quality

The joining of dissimilar Al alloys Al 6061-T6 and Al 7075-T6 plates was carried out using friction stir welding (FSW) technique. The joining of two dissimilar Al alloys Al 6061-T6 and 7075-T6 is not possible by the fusion welding technique because of the crack formation on the surface. In this study experiment welding of these alloys is done by the FSW technique and results of tensile strength and surface roughness of the weld were satisfactory. The plunge depth (tool pin length), rotational speed of the tool and welding speed were the parameters taken into consideration. The ultimate tensile of the weld were output and response factors of this study. The effect of the rotational speed and welding speed on the tensile strength of the weld was found in this study experiment. The effect of plunge depth (tool pin length) on the tensile strength of the weld of Al 6061-T6 and Al 7075-T6 of 6 mm thick plates is determined. Taguchi S/N ratio method were used on the rotational speed and welding speed parameters for maximum tensile strength of the weld. The effect of base metal thickness on the tensile strength of the weld is also determined. The relation between tool pin length and thickness of weld plate was obtained in this study experiment.