On August 17, 2026

EXPERIMENTAL & INVESTIGATION OF FSW ON AL – 6061 –MG T6 DISSIMILAR JOINTS

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Friction Stir Welding (FSW) is a solid-state joining technique that has shown significant
potential for welding dissimilar materials such as aluminum and magnesium alloys, which are
difficult to join using conventional fusion welding methods due to large differences in their
physical, thermal, and metallurgical properties. During friction stir welding, contact between the
rotating, wear-resistant tool shoulder, the pin, and the work piece produces frictional energy.
Additional thermal energy develops because of intense material deformation and internal
adiabatic heating. The combined effect raises the temperature enough to soften the surrounding
metal while keeping it below its melting temperature, making the technique a solid-state joining
process. The rotating tool then travels along the joint path through a region of softened material,
creating a continuous plasticized zone around the pin.
As the tool advances, the front surface of the pin displaces the softened material toward the rear
side. The specially designed pin geometry improves material movement and promotes uniform
flow around the tool. At the same time, the shoulder applies compressive pressure that forges the
displaced material together, producing a sound metallurgical bond. Joint formation occurs

through extensive plastic deformation accompanied by dynamic recrystallization, which refines
the microstructure and enhances the mechanical integrity of the welded region.
The proposed project aims to investigate the feasibility and performance of friction stir welded
aluminum alloy AA6061-T6–magnesium AZ-31BS dissimilar joints through an experimental
approach. The project focused on analyzing the effects of process parameters and tool design on
joint formation, mechanical properties, and microstructural evolution at the
aluminum–magnesium interface. Planned experimental work includes tensile testing, hardness
measurement, and microstructural characterization to evaluate joint strength, failure behavior,
material flow, and interfacial bonding. The outcomes of this research included improved
understanding of process–structure–property relationships and identification of optimal welding
conditions for aluminum–magnesium dissimilar joints. The proposed work aimed to contribute to
the development of reliable joining solutions for lightweight and high-performance.

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