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<p>The demand for steel–aluminum multi-material structures are rapidly growing in the transportation industries, including the automobile, aerospace, and shipbuilding sectors. In this study, a 3&#xa0;mm thick AA 6061-T6 alloy and IS 2062 FE410WA steel alloy were butt-welded using the friction stir welding (FSW) process. The objective of this study was to investigate the effects of tool rotational speed (TRS), tool tilt angle (TTA), and welding speed (WS) on weld quality. Each variable was tested at three distinct levels using the Taguchi L<sub>9</sub> orthogonal array. For the characterization of the welded coupons, visual inspection, tensile testing, and macro-analysis of the weld cross sections were carried out. Confirmation tests were conducted under optimal conditions (TRS = 1070&#xa0;rpm, WS = 50&#xa0;mm/min, TTA = 1°), yielding an average UTS of 167.9 ± 2.8&#xa0;MPa, indicating good repeatability. This study uniquely examines the influence of process parameters on tensile properties, and the integration of the Taguchi design with microstructural correlation and microhardness mapping presents a distinctive approach to joint optimization. The novelty of this study lies in the integrated optimization of friction stir welding parameters for AA6061-T6 and IS 2062 FE410WA, with a comprehensive analysis of microstructural and microhardness correlations, a topic not extensively addressed in previous studies.</p>

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Process Parameter Optimization for Dissimilar Friction Stir Welding of Aluminum and Steel

  • 期刊论文

  • 发表日期：

    2025年8月26日

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  • Yogesh R. Gunjal,
  • Vijay S. Gadakh,
  • Mrinal Sahu,
  • Vishvesh J. Badheka,
  • Manank M. Patel

摘要

The demand for steel–aluminum multi-material structures are rapidly growing in the transportation industries, including the automobile, aerospace, and shipbuilding sectors. In this study, a 3 mm thick AA 6061-T6 alloy and IS 2062 FE410WA steel alloy were butt-welded using the friction stir welding (FSW) process. The objective of this study was to investigate the effects of tool rotational speed (TRS), tool tilt angle (TTA), and welding speed (WS) on weld quality. Each variable was tested at three distinct levels using the Taguchi L9 orthogonal array. For the characterization of the welded coupons, visual inspection, tensile testing, and macro-analysis of the weld cross sections were carried out. Confirmation tests were conducted under optimal conditions (TRS = 1070 rpm, WS = 50 mm/min, TTA = 1°), yielding an average UTS of 167.9 ± 2.8 MPa, indicating good repeatability. This study uniquely examines the influence of process parameters on tensile properties, and the integration of the Taguchi design with microstructural correlation and microhardness mapping presents a distinctive approach to joint optimization. The novelty of this study lies in the integrated optimization of friction stir welding parameters for AA6061-T6 and IS 2062 FE410WA, with a comprehensive analysis of microstructural and microhardness correlations, a topic not extensively addressed in previous studies.