Friction stir welding of dissimilar Al alloys: effect of process parameters on mechanical properties

In the present experimental study, two dissimilar sister aluminum alloys, 5083 and 5086, are welded through friction stir welding process. Different experiments are conducted on vertical milling machine through a fixture design and firm holding welding plates on it. These experiments are performed by varying welding parameters including welding speed, rpm, different pin profiles, tool tilt angle at five levels each. Two different mechanical properties of the welded specimen (i.e. tensile strength and percentage of elongation) have been tested and compared with the base metals to find out the joint efficiency. Also it is observed that rpm, tool tilt angle and different pin profiles make significant impacts on friction stir welded joints. Tool rpm increases the tensile strength to an extent. Also, tool pin profile affects the stirring or plastic flow of material under tool shoulder. It is shown through visual and optical analysis that surface finish and weld quality of joints depend on tool tilt angle.