Abstract:
Friction stir welding (FSW) is a solid-state joining process widely used for joining similar
and dissimilar materials and achieving high-quality welds. In this project, the aim was to
investigate the effects of process parameters on the weld quality and mechanical properties of
FSW joint for two different grades Aluminum. The objective of this project was to investigate
the feasibility of friction stir welding (FSW) on a milling machine and evaluate the quality of
the welded joint through simulation and testing. The FSW process was simulated using finite
element analysis (FEA) to predict the temperature distribution, residual stresses, and
deformation during the welding process. The mechanical properties, including tensile strength
and hardness, were evaluated through standard testing methods. The results demonstrated the
successful fabrication of aluminum-to-steel joints using the FSW process. The welds exhibited
a fine-grained microstructure and high joint strength, indicating the feasibility of using FSW
for such dissimilar material combinations. This study provides valuable insights into the FSW
process for two different grades Aluminum joints and contributes to the development of
reliable welding techniques for similar applications.
