Friction Stir Welding of Dissimilar Aluminum Alloys: Process Parameters and Joint Characterization

Friction stir welding (FSW) has been recognized as a viable solid-state joining technology for dissimilar metals. This study tests the feasibility of the FSW for joining different aluminum alloys 1050 and 2024 with a manual vertical milling machine and a customized FSW tool. Finite element analysis was used to simulate the FSW process and estimate temperature distribution, residual stresses, and deformation at the joint. The rotating speed, welding speed, plunge depth, and axial force were set to 850 RPM, 2 mm/min, 2.5 mm, and 1.5 kN respectively. Tensile testing found a joint efficiency of approximately 66%. The highest temperature reached on the milling machine throughout the FSW process was 380°C, which is close to the simulation’s predicted temperature of 493°C. The difference is attributable to internal material flaws, simulation precision constraints, plate movements during the FSW process. The feasibility of the work was confirmed after the creation of strong FSW joint between dissimilar aluminum alloys. Further research should focus on other industrial alloy grades, microstructural analysis and process optimization.