EFFECT OF MICROSTRUCTURE AND MECHANICAL PROPERTIES OF FRICTION STIR WELDED DISSIMILAR AA5083-AA6061 ALUMINIUM ALLOY JOINTS

Abstract

Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace aluminum and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 5mm thicknessAA6061 and AA5083 dissimilar Aluminum alloys. Aluminum alloy light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so aluminum alloy has selected in this FSW technique. In this welding when two metals are joined with the help of heat generated by rubbing metals against each other. The friction stir welding is mostly used for joining aluminum alloys. The main defects occurring in this welding are holes, material flow rate. These defects are mainly caused due to improper selection of welding parameters. In this project the mechanical properties of FSW dissimilar aluminum alloy AA5083 and AA6061has tested with the help of universal testing machine, hardness testing by Vickers hardness at various zones of the welded joints. In this experimental the testing of mechanical properties based on the input parameters such as rotational speed, tool speed and axial force with proper welding parameters. Finally, the experimental results will be compared with microstructures are analyzed by optical microscope. It is observed that the grain size is decreased in friction stir welding with circle with threaded pin profile. Also have better mechanical properties and these S properties have been correlated with microstructures. Higher mechanical properties are obtained with square pin profile tool at a rotation speed of 1400rpm and welding speed of 60mm/min. .