International Journal of Manufacturing and Materials Processing
Experimental Investigation of FSW on Al 6061-T6 MG Dissimilar Joints
1. Student, M. Tech., Department of Machine Design, Mallareddy
College of Engineering and Technology (Affiliated to JNTU,
Hyderabad), Secunderabad, Telangana, India
2. Associate Professor, Department of Machine Design, Mallareddy College of Engineering and Technology (Affiliated
to JNTU, Hyderabad), Secunderabad, Telangana, India
Abstract
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 FSW, 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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