Sustainable Processing of Dissimilar Aluminium Alloy Joints by Friction Stir Welding

Abstract

Friction stir welding is one of the unique solid state welding technique that is fast gaining importance because of its excellent properties pertaining to the strength, wear, hardness and better joining capabilities. The friction stir welding technique is effectively used in this research to join 5 mm thick dissimilar aluminium alloys of AA 7075 and AA 5052 grade. The friction stir welding joints are obtained by using three different tool profiles viz., straight cylinder, taper cylinder, and straight triangular at a speed of 800, 1000, 1200 rpm and a feed rate of 100, 120, 140 mm/min. The experiments are designed based on L9 orthogonal array considering Taguchi techniques. From the experimental results, the process methodology is validated and the outcomes of the experiment are considered for fabrication of strong joints. The design and optimization of the process has led to better process control and thereby extended its scope for the use of the optimized process parameters for joining dissimilar aluminium alloys in real time engineering applications with sustained methodologies involving reduced dwell time and optimized friction forces and torque during the friction stir welding of dissimilar aluminium alloys.