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<p>Dissimilar welding of AA6061 and AA7075 aluminium alloys is crucial for lightweight structures but is limited by heat-affected softening and intermetallic formation. This study investigates submerged friction stir welding (SFSW) of AA6061–AA7075 joints using a Taguchi L9 design with pin diameter (4-6&#xa0;mm), rotational speed (800-1200&#xa0;rpm), and welding speed (40-80&#xa0;mm/min) as control factors. Tensile testing showed ultimate tensile strength in the range of approximately 220-260&#xa0;MPa, with the best joint achieving about 15-20% improvement over the lowest-strength condition, while yield strength varied between roughly 120-160&#xa0;MPa and elongation between about 10-35%. ANOVA indicated that rotational speed had the highest contribution to UTS, whereas welding speed dominated the variation in yield strength, and pin diameter significantly influenced elongation. Fatigue crack growth tests revealed that the highest-strength weld exhibited the lowest Paris-region slope and the slowest crack growth rate over the investigated ΔK range, confirming superior fatigue resistance compared with medium- and low-strength joints. These results demonstrate that properly optimized SFSW parameters can simultaneously enhance static strength and fatigue performance of AA6061–AA7075 dissimilar joints, supporting their use in demanding structural applications.</p>

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Influence of Process Parameters on Joints Properties of Submerged Friction Stir Welded Dissimilar 6061-7075 Aluminium Alloys

  • 期刊论文

  • 发表日期：

    2026年4月28日

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  • Vijay Chouhan,
  • Lokesh Kumar Boriwal,
  • Archana Singh,
  • Ratnesh Kumar Raj Singh,
  • Krishnakant Dhakar

摘要

Dissimilar welding of AA6061 and AA7075 aluminium alloys is crucial for lightweight structures but is limited by heat-affected softening and intermetallic formation. This study investigates submerged friction stir welding (SFSW) of AA6061–AA7075 joints using a Taguchi L9 design with pin diameter (4-6 mm), rotational speed (800-1200 rpm), and welding speed (40-80 mm/min) as control factors. Tensile testing showed ultimate tensile strength in the range of approximately 220-260 MPa, with the best joint achieving about 15-20% improvement over the lowest-strength condition, while yield strength varied between roughly 120-160 MPa and elongation between about 10-35%. ANOVA indicated that rotational speed had the highest contribution to UTS, whereas welding speed dominated the variation in yield strength, and pin diameter significantly influenced elongation. Fatigue crack growth tests revealed that the highest-strength weld exhibited the lowest Paris-region slope and the slowest crack growth rate over the investigated ΔK range, confirming superior fatigue resistance compared with medium- and low-strength joints. These results demonstrate that properly optimized SFSW parameters can simultaneously enhance static strength and fatigue performance of AA6061–AA7075 dissimilar joints, supporting their use in demanding structural applications.