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<p>This study investigates the dissimilar friction stir welding (FSW) of AA5083-O and AA6061-T6 aluminum alloys under water-based cooling-assisted conditions. The process parameters—rotational speed (800-1200&#xa0;rpm) and traverse speed (60-100&#xa0;mm/min)—were optimized using Taguchi analysis to achieve defect-free welds with enhanced mechanical and tribological properties. Microstructural evaluation revealed significant grain refinement in the stir zone, attributed to severe plastic deformation and suppressed heat input. The cooling-assisted FSW joints exhibited up to 27% higher ultimate tensile strength (UTS) and 19% greater hardness compared to conventional FSW, reaching maximum values of 179.53&#xa0;MPa UTS and 92.29 HV respectively. Furthermore, a 49% reduction in wear rate was achieved (from 1.12 × 10<sup>−5</sup> to 0.58 × 10<sup>−5</sup> mm<sup>3</sup>/Nm), indicating enhanced surface integrity. These improvements are linked to minimized thermal softening and finer microstructures due to external cooling. The results confirm that cooling-assisted FSW is a promising approach for fabricating high-integrity dissimilar aluminum joints in structural and transportation applications.</p>

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Experimental Investigation on Cooling-Assisted Friction Stir Welding of Dissimilar AA5083 and AA6061 Alloys

  • 期刊论文

  • 发表日期：

    2025年10月21日

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  • Vishal Bhojak,
  • Jinesh Kumar Jain,
  • M. K. Banerjee,
  • Tejendra Singh Singhal

摘要

This study investigates the dissimilar friction stir welding (FSW) of AA5083-O and AA6061-T6 aluminum alloys under water-based cooling-assisted conditions. The process parameters—rotational speed (800-1200 rpm) and traverse speed (60-100 mm/min)—were optimized using Taguchi analysis to achieve defect-free welds with enhanced mechanical and tribological properties. Microstructural evaluation revealed significant grain refinement in the stir zone, attributed to severe plastic deformation and suppressed heat input. The cooling-assisted FSW joints exhibited up to 27% higher ultimate tensile strength (UTS) and 19% greater hardness compared to conventional FSW, reaching maximum values of 179.53 MPa UTS and 92.29 HV respectively. Furthermore, a 49% reduction in wear rate was achieved (from 1.12 × 10−5 to 0.58 × 10−5 mm3/Nm), indicating enhanced surface integrity. These improvements are linked to minimized thermal softening and finer microstructures due to external cooling. The results confirm that cooling-assisted FSW is a promising approach for fabricating high-integrity dissimilar aluminum joints in structural and transportation applications.