Similar and dissimilar 5754 and 6063 aluminum alloy joints by friction stir welding

The relatively new solid state welding process friction stir welding (FSW) was applied in this research work to join similar and dissimilar aluminum alloys AA5754-H22 and AA6063-T4. Different welding rotational speed and transverse speed applied. The joint which was fabricated using tool rotational speed of 2000 rpm and transverse speed of 4 mm/min yielded the best mechanical properties. Soundness of joint was proved by non-destructive tests such as visual inspection and radiography. The global mechanical behavior of the similar welds is very similar to that of the base material. For dissimilar weld important losses in ductility was reported. Microstructural evaluation of fractured surface showed that ductile fracture was the major fracture mechanism of similar and dissimilar welds.