Effect of faying surfaces and characterization of aluminium AA6063–steel AISI304L dissimilar joints fabricated by friction welding with hemispherical bowl and threaded faying surfaces

This work describes the effect of newly introduced faying surfaces on microstructure and mechanical properties dissimilar weld joints AA6063 AISI304L alloys that are fabricated through rotary friction welding process (RFW). The experiments were done as six different experimental methods (‘A’ to ‘F’) at 1300 rpm rotation, 18 MPa pressure (FP), 24 upset (UP) 5 s time (FT) with hemispherical bowl thread 1 mm pitch specimens. zones characterized by macro microstudy, energy dispersive X-ray spectroscopy (EDS) spectrums, tensile properties, Vickers microhardness, impact toughness fractography. results showed these surface modifications strengthen bonding between specimens influences performance joints. better than threaded surfaces. Axial shortenings within acceptable limit in range 20–27 mm. Macro microstructural studies defect-free strong alloys. alloy formed a U-shaped interface (WI) EDS proved formation Fe–Al intermetallic element ‘O’ zone. joint efficiency for all was around ≥100%. Maximum strength recorded 238 method F. good hardness property nearby WI, A yielded maximum joint.