Effect of welding process parameters on surface topography and mechanical properties of friction-stir-welded AA2024/AA2099 alloys

Abstract The joining of two materials with different chemical composition was a major setback for conventional methods of metal joining. The results of this welding were showing considerably great improvement in the aspects of quality of weld, amount of heat generated, uniform distribution of material, refined microstructure, enhanced tribology, materials flowing pattern, good strength with reduced internal stresses. Optimized parameters were estimated by using Desirabilty approach and Response surface methodology. Optimum parameter combination for dissimilar material welding was observed to be 913.74 rpm, 45 mm min −1 and 8kN. The desirability values for dissimilar welding process were 0.912 respectively. The grain enhancements were decreased in the range of WC > WT > HAZ > Parent material. The wear rate of dissimilar AA2024 and AA2099 were superior as the wear value increases from 0 to 50 μ m in the nugget zone. The coefficient of friction value remains constant throughout the wear experiment ranges from 0.3 to 0.55. A steady state friction value of 3N to 5N is observed when sliding distance increases. The wear loss was measured by finding the difference between initial weight and final weight and found as in the range from 0.2283 g to 0.4866 g.