Process parameters study on FSW joint of dissimilar metals for aluminum–steel

This research aimed to weld dissimilar metals joints, AA6061 aluminum alloy and SS400 low-carbon steel, and find the optimum operating conditions of friction stir welding. In dissimilar metals butt joint by friction stir welding procedures, there are four major controllable factors, which are tool rotation speed, transverse speed (feed rate), tool tilt angle with respect to the workpiece surface and pin tool diameter. Understandably, not all the controllable factors are included in this article. The quality of dissimilar metals butt joints is evaluated by the impact value, which has not been discussed in literatures. In addition, an uncontrollable parameter, which is the tensile strength, is used to double-check its quality based on the excellent impact value. Analysis of variance (ANOVA) is used to analyze the experimental data. The Taguchi technique with ANOVA is also used to determine the significant factors of performance characteristics. The results are expected to serve as references to overland and aquatic transportation machines for weight reduction.