Study of Similar/Dissimilar Joining Between Al6063-Al6063, EN24-EN24, and Al6063-EN24 Rods Using Rotary Friction Welding (RFW)

In the present study, attempt was made to join similar and dissimilar materials, i.e., EN24 (ferrous) and Al6063 (non-ferrous) by solid state welding technique, i.e., Rotary Friction Welding (RFW). Three different combinations viz. Al6063-Al6063 (similar), EN24-EN24 (similar) and Al6063-EN24 (dissimilar) were prepared followed by further characterization viz., Tensile strength, microhardness, welding joint efficiency and Charpy impact tests. Results showed weld joint strengths of both similar joints, close to the respective parent material. In case of dissimilar joint, the strength was comparable with the weaker material (Al-6063). Highest joint efficiency of 100.65% was obtained in case of EN24-EN24 joint where the failure was noticed at the base metal. Corresponding hardness values are also very high in the joint area (>600 HV as compared to 240 HV for parent material) which indicates formation of hard microstructure. In all other cases, the weld joints failed and weld efficiency was 93.45% and 82.38% for Al6063-Al6063 and Al6063-EN24 joints respectively.