Investigation of Effect of Process Parameters on Friction Stir welded dissimilar AA6061 T6 and AA7075 T651

The process of welding isasignificant manufacturing process used to join metal alloys. Friction stir welding (FSW) is a method of solid-state weldingtechnique which heats the metalto the plasticized statebecause of the generated heat by friction due to the stirring action of the non-consumable tool over the surface of the base metals, resulting in sound weld.The present study focuses on theeffect of various welding process parameters ondissimilar welding of AA6061 T6 andAA7075 T651aluminium alloys in order to improve the mechanical strength properties. In this study, conical and cylindrical tool pin profilesare chosen toexecute the welding process.The process parameters considered for the study to determine the ultimate tensile strength (UTS), elongation and hardness of the six welded joints are tool geometry, rotational spindle speed of about 600,800 and 1000 RPM and feed rate of about 30,45,60 mm/min respectively. The results inferred that the combination of rotational spindle speed, feed rate and tool pin profile affects the average hardness andmicrostructure of the welded area.