Effect of Tool Profile Influence in Dissimilar Friction Stir Welding of Aluminium Alloys (AA5083 and AA7068)

Friction stir welding is an innovative welding process for similar and dissimilar joining of the materials effectively. FSW simply modified the grain structure and also improved the strength of the joints for any type of alloying elements. This experimental study planned to carry out the joining process for dissimilar materials such as aluminium alloys 5083 and 7068. Three different types of tools are involved to find the ultimate tensile strength and Vickers hardness. The tool types are straight cylindrical tool, taper cylindrical tool, and triangular tool. The process factors for this investigation are a rotational speed of 800, 1000, 1200, and 1400 rpm, welding speed of 30, 40, 50, and 60 mm/min, axial force of 3, 4, 5, and 6 kN, and plate thickness of 5, 6, 7, and 8 mm. The hardness value and the ultimate tensile strength were increased in the welding zone, which proves the effects of tool profiles are efficiently utilized.