Mechanical Characterization of Rotary Friction Welded Dissimilar Aluminium Alloys

Joining of the similar & dissimilar materials alloys using heat of the friction in currently being used, especially for non-ferrous alloys which are considered as non-weldable alloys. Al 2024-T6 & Al 6061-T6 having length of 70mm and 12mm diameter were welded by using the friction welding process. Similar and dissimilar welded samples were obtained by applying different combinations of welding parameters like friction pressure 30bar, forging pressure from 50 to 60 bar, and rotational speed of 2200 rpm. Vickers microhardness and Tensile test was performed on similar and dissimilar welded samples. Test shows that ultimate tensile strength and hardness of the similar welded joint was greater than their respective base metals welds. Dissimilar weld samples have hardness and ultimate tensile strength greater than the base Al 6061-T6, and less than the base Al 2024-T6. From results, it was clearly shown that as forging pressure increased from 50 to 60 bar, ultimate tensile strength and hardness of the similar and dissimilar welded samples increased. Joints were analysed to investigate the fractography of all welded samples. All welded samples fractured on the base metal alloy and show the formation of the cup and cone like structure which indicate the ductile fracture of the joints.