Microstructure, microhardness and mechanical behavior of dissimilar AA7075/AA6061 alloys under friction stir welding

Friction stir welding (FSW) of dissimilar AA6061 and AA7075 aluminum alloys faces challenges such as an unclear forming mechanism and low welding efficiency. In order to improve welding efficiency and elucidate the variations in metallography, Microhardness, and mechanical properties of dissimilar alloy FSW joints, this article designed FSW experiments using the Taguchi method with welding speeds ranging from 600 to 1000 mm/min. We studied the relationship between material mixing and welding defects through macroscopic metallography, microscopic metallography, and Microhardness, while the impact of welding parameters on the microstructure and properties was evaluated. The results show that void defects do not exist in dissimilar alloy FSW joints, and the Microhardness changes are “U” and “W” shaped. Material mixing played a decisive role in determining the microstructure and properties of dissimilar aluminum alloy FSW joints, with increased rotational speed enhancing material flow. The order of influence on the mechanical properties of the joint was found to be plunge depth, welding speed, and rotational speed. Under the conditions of 1000 mm/min, 2400 rpm, and 0.25 mm, the yield strength (YS) and ultimate tensile strength (UTS) of the dissimilar alloy FSW joints reached 87.3% and 73.4% of the AA6061-T6 alloy, respectively.