Feasibility and Insights into the Optimization and Characterization of Friction Welded Aluminum–Steel Dissimilar Joints

This research article focuses on addressing the challenges associated with joining dissimilar metals through the application of solid-state welding techniques, specifically Friction Welding (FW). The study aims to develop optimal welding conditions, tools, and parameters for achieving a successful Aluminum–Steel (Al–Fe) butt joint. The resulting weld is extensively characterized through mechanical tests, microstructure analysis, and micro hardness measurements. Additionally, finite element analysis is conducted to simulate the behaviour of the prototype engine valve. The findings provide valuable insights into the feasibility and performance of friction welding for dissimilar metal joints, contributing to the further development and understanding of this welding technique.