Author : Neha Rani, Ram Niwas Bishnoi and Ajay Mahendru

In present work, an investigation has been carried out on single and double pass friction stir welding (FSW) of two
dissimilar aluminium alloys AA6061 and AA8011 using high carbon high chromium alloy steel tool. Study of the
different mechanical properties such as tensile strength and micro hardness of the joints was carried out with the use of different tool pin profiles i.e. straight cylindrical, threaded and tapered cylindrical for single pass and double pass welding at constant tool rotational speed of 1400 rpm and traverse speed of 45 mm/min. Shape of the tool pin profile and number of passes are process variables. Results show that maximum tensile strength occurs across the double pass as compared to the single pass. It has observed that hardness value of single sided welded joints is slightly greater than double sided welded joints. From this investigation it is found that threaded tool pin profile produces mechanically sound weld and superior tensile properties as compared to other joints.

Keywords: Friction Stir Welding; Aluminium Alloys AA6061 & AA8011; Tool Pin Profile; Mechanical Properties.

Article published in International Journal of Current Engineering and Technology, Vol.5, No.6 (Dec-2015)