Friction stir welding of AA2024 and AA6061 using various pin profile

The research work deals with to join two dissimilar aluminum alloys by solid state welding process compared to fusion welding processes and compared with fusion welding process, fusion welds tend to produce more defects while joining dissimilar materials. The major problem of the two dissimilar metals involve in welding process have different mechanical properties and microstructures which in turn may affect welding parameters like weld current, hold time, weld force etc. In order to overcome these issues, Friction Stir Welding (FSW) can be used to get rid of defects since it uses a non-consumable tool and also produces defect free welds compared to other welding processes. This thesis work aims to joining an aluminum alloy of 2024 and aluminum alloy of 6061. The plates are joined by means of octagon probe tool made of high carbon high chromium steel (D2 tool steel). Other issues while welding dissimilar aluminum alloys are phase transformation change and selection of welding parameters (rotational speed, transvers speed, pin diameter, shoulder diameter, D/d ratio and etc.) From conducted trail experiment aluminum alloy of 2024 and aluminum alloy of 6061 by using octagon probe tool made by HC-HCR tool it was observed that a lower welding speed 500 rpm at starting stage lack of filling took place and after thermo-mechanical heating took place that produce better weld while compared to weld at higher speeds (710 rpm, and 1000 rpm) with same transvers speed of 20 mm/min.