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<p>This study offers a comparative investigation of the friction stir welding (FSW) and tungsten inert gas (TIG) welding processes of dissimilar AA6061 and AA7075 aluminum alloys. In the FSW process, the welding parameters adopted were a rotation speed of 1000&#xa0;rpm and a traverse speed of 60&#xa0;mm/min. In the TIG welding process, a welding current of 140&#xa0;A was used. From the microstructural studies, equiaxed dynamically recrystallized grains have been observed in the FSW joint, while the TIG welded joint has shown dendritic microstructures and segregation in the fusion zone. In the FSW joint, the maximum tensile strength of 268&#xa0;MPa has been achieved, which is 29% greater than the tensile strength of the TIG welded joint. From the microhardness profile, a maximum hardness of 122 HV has been achieved in the FSW joint compared to TIG welded joint. From the fracture studies, it has been revealed that the FSW joint has shown ductile fracture with uniform dimples, while the TIG welded joint has shown a mixed-mode fracture. This study has demonstrated the better mechanical and microstructural stability of the FSW joint compared to the conventional TIG welding process.</p>

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A comparative study on friction stir and TIG welding of dissimilar AA6061–AA7075 aluminium alloys

  • 期刊论文

  • 发表日期：

    2026年3月17日

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  • M. Ramesh,
  • T. Suresh,
  • G. Dhanesh,
  • D. Dev Prasanth,
  • M. Mohamed Irfan,
  • Hari Vardhan Sampath

摘要

This study offers a comparative investigation of the friction stir welding (FSW) and tungsten inert gas (TIG) welding processes of dissimilar AA6061 and AA7075 aluminum alloys. In the FSW process, the welding parameters adopted were a rotation speed of 1000 rpm and a traverse speed of 60 mm/min. In the TIG welding process, a welding current of 140 A was used. From the microstructural studies, equiaxed dynamically recrystallized grains have been observed in the FSW joint, while the TIG welded joint has shown dendritic microstructures and segregation in the fusion zone. In the FSW joint, the maximum tensile strength of 268 MPa has been achieved, which is 29% greater than the tensile strength of the TIG welded joint. From the microhardness profile, a maximum hardness of 122 HV has been achieved in the FSW joint compared to TIG welded joint. From the fracture studies, it has been revealed that the FSW joint has shown ductile fracture with uniform dimples, while the TIG welded joint has shown a mixed-mode fracture. This study has demonstrated the better mechanical and microstructural stability of the FSW joint compared to the conventional TIG welding process.