A Critical Review on Friction Stir

Welding of Dissimilar Aluminium Alloys

Munna Singh Dahiya, Vikas Kumar and Shubham Verma

Abstract Friction stir welding (FSW) is a solid-state joining process having capa-
bility of joining materials which differ in chemical composition, properties, etc.,
and where fusion can lead to harmful reactions. Nowadays, the arena of aerospace,
railway, ship building industries, etc., are moving towards the use of this technique
as compared to fusion welding process for the fabrication of structural parts. It is
energy-efficient, eco-friendly and versatile process of joining. In the current study,
an attempt has been made to study the effect of process parameters, i.e. rotational
speed, welding speed, tool tilt angle, dwell time, etc., on the weld characteristics of
dissimilar aluminium alloys. Moreover, difficulties and other issues related to FSW
of dissimilar metals are addressed to provide guidelines to research community to
carry out extensive research in this field.

Keywords FSW · Dissimilar alloys · Weld characteristics

1 Introduction

Recently, manufacturing industries are moving towards the use of aluminium and its
alloys owing to its unique features, i.e. high strength-to-weight ratio, corrosion resis-
tance, good formability, etc. The conventional welding of these alloys are problematic
and occurrence of various defects such as voids, hot cracking, distortion, precipitate
dissolution, loss of work hardening, and hot cracking. To overcome the problems of
fusion welding of low metal alloys, The Welding Institute (TWI, UK) invented a new
welding technique, i.e. friction stir welding (FSW), in 1991. The schematic diagram
of process principle for FSW is shown in Fig. 1. It consists of non-consumable tool
with specially design pin and shoulder. The pin plunges between the faying surfaces
of the plates [1]. The shoulder is in direct contact with the workpiece surface, and

M. S. Dahiya (B) · V. Kumar · S. Verma

National Institute of Technology, Kurukshetra, India
e-mail: munna.dahiya93@gmail.com
S. Verma
e-mail: shubham6140005@gmail.com
© Springer Nature Singapore Pte Ltd. 2019 707
K. Shanker et al. (eds.), Advances in Industrial and Production Engineering, Lecture
Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-13-6412-9_66
708 M. S. Dahiya et al.

Fig. 1 Principle of friction stir welding (Verma and Misra [2])

due to its rotational movement on the workpiece, friction heat is generated which
results in softening of the faying surface material. Due to the translation and rotational
movements of tool, solid-state joint is produced. In the current study, an attempt has
been made to explain the effect of process parameters on the weld characteristics of
dissimilar aluminium alloys.

2 Process Parameters

In friction stir welding, the process parameters are mainly classified into three groups:
Tooling-related parameters: shoulder and pin material, pin profile, pin and shoulder
diameter, pin length, shoulder shape, feature geometry, thread pitch, etc.
Machine-related parameters: traverse speed, plunge force or depth, spindle speed,
tool tilt angle, etc.
Other parameters: anvil material, anvil size, workpiece size, workpiece properties,
etc. The effected process parameters are exemplified using a cause–effect diagram
in Fig. 2.

3 Literature Review

FSW process has capability of joining similar and dissimilar aluminium alloys.
Owing to this, manufacturing industries are moving towards the use of this
A Critical Review on Friction Stir Welding … 709

Fig. 2 Cause–effect diagram [2]

technology. A comparative study of published research work on FSW of dissimi-

lar aluminium series is shown in Fig. 3.
It is clear from the figure that maximum work has been done on 6xxx-7xxx series
of aluminium alloys and minimum work is done on 5xxx-6xxx series. In this chapter,
an attempt has been made to summarize the work already carried out and to provide
a guideline for future research work on joining of dissimilar aluminium alloys. The
literature review is classified into three different groups as shown in Fig. 4 (Tables 1,
2 and 3).

Fig. 3 Previous work on

FSW of dissimilar
No.of publications
aluminium series
17% 11%
18% 5xxx-6xxx
5xxx-7xxx
24% 6xxx-7xxx
2xxx-7xxx
30% 2xxx-6xxx
710 M. S. Dahiya et al.

Fig. 4 Classification of the literature survey

Table 1 Optimization of FSW parameters

Researchers Workpiece Tool Conclusion
Ataya et al. [3] AA7075 H13 • They concluded that
AA5083 welding speed has no
significant effect on weld
characteristics
Kundu and Singh [4] AA5083 H13 • The entire fabricated
AA5086 joints have less joint
efficiency than the parent
metal owing to dynamic
recrystallization
• The maximum tensile
strength is obtained at a
rotational speed of
1000 rpm, a tilt angle of 2
degree and a minimum
value of feed rate
Ravikumar et al. [5] AA6061 H13 • Better weld
AA7075 characteristics are
obtained at a rotational
speed of 900 rpm and a
feed rate of 100 mm/min
Gupta and Singh [6] AA3003 H13 • They employed Taguchi
AA5052 method for designing the
experiment of FSW of
AA3003 and AA5052
plates
(continued)
A Critical Review on Friction Stir Welding … 711

Table 1 (continued)
Researchers Workpiece Tool Conclusion
Bozkurt [7] AA2024 H13 • Taguchi’s L9 orthogonal
AA5754 array are used for
conducting the
experiments
• The contributions of each
parameters are 53.66% of
rotational speed, 23.74%
of tool tilt angle, 12.54%
of tool plunge depth and
5.45% of dwell time
Gungor et al. [8] AA5083 H13 • The joint efficient is found
AA6082 to be 38% less than that of
the similar fabricated joint
• Desirable weld
characteristics are
obtained at 1250 rpm tool
rotation, 64 mm/min feed
rate and 2° tool tilt angle
Elanchezhian et al. [9] AA6062 H13 • Taguchi L9 orthogonal
AA8011 array are used optimizing
the process parameters of
FSW process. The
maximum UTS of
153 MPa is obtained
Koilraj et al. [10] AA2219 H13 • They observed 66%
AA5083 contribution of D/d ratio
on the FSW process
Giraud et al. [11] AA7020 H13 • Most efficient result is
AA6060 obtained at rotational
speed from 1000 to
2000 rpm and feed rate
from 300 to 1100 mm/min
Shojaeefard et al. [12] AA7075 H13 • Defect-free friction stir
AA5083 welds have been produced
for the dissimilar alloy
system AA5083 and
AA7075
• A sound weld is obtained
at a rpm of 1400 rpm and
feed of 20 mm/min
(continued)
712 M. S. Dahiya et al.

Table 1 (continued)
Researchers Workpiece Tool Conclusion
Singh and Dhuria [13] AA2014 H13 • They employed Taguchi
AA7075 method for
experimentation and
optimizing the process
parameters for FSW. It is
concluded that tool
material has significant
effect on the joint
efficiency
Hema et al. [14] AA6061 H13 • RSM is used for designing
AA2014 the experiments. The
maximum tensile strength
of 133 MPa is obtained at
optimum values of
2000 rpm, 37 mm/min of
feed rate and 75 kN of
axial force
Sadeesh et al. [15] AA2024 AISI H13 • Five different tool pin
AA6061 profiles are used for
fabricating the joint by
FSW. It is observed that
square pin profile
produces sound weld as
compared to other pin
profile
• The fabricated joint
efficiency is maximum at
a rotational speed of
1000 rpm and a welding
speed of 40 mm/min with
square pin profile
da Silva et al. [16] AA2024 H13 • They used threaded and
AA7075 unthreaded pin profiles
tool for fabricating the
joint and observed that
threaded tool pin profile
tools produce sound weld.
This is due to the proper
mixing of materials due to
thread on the pin
A Critical Review on Friction Stir Welding …
Table 2 Metallurgical aspect and mechanical aspects
Researchers
Ilangovan et al. [17]
Giraud et al. [11]
Vinayak and Bhatwadekar
[18]
Hariharan and Golden
Renjith Nimal [19]
Cavaliere et al. [20]
Palanivel et al. [21]
Infante et al. [22]
Rodriguez et al. [23]
713
Workpiece Tool Conclusion
AA6061 HSS • Defect-free joint is
AA5086 obtained with a tensile
strength of 140 MPa and
micro-hardness of 115HV
• The joint efficient is found
to be 30% less than that of
the similar fabricated joint.
This is attributed towards
difference in heat
generation during the
process
AA7020 HSS • They employed FSW for
AA6060 joining of dissimilar metal
alloys. The joint efficient is
found to be satisfactory
AA1100 H13 • The fabricated joint is
AA6101 defect free with a joint
efficient less than that of
the parent metals
AA6061 Hchcr • The grain size of 100
AA7075 microns is observed in the
nugget zone owing to
dynamic recrystallization
AA2024 H13 • They employed FSW for
AA7075 joining AA2024 and
AA7075 plates and
measured the fatigue
properties of the weld
AA6351 HCHCr • They observed that square
AA5083 pin profile produces higher
tensile strength than the
other pin profile owing to
pulsating moment of the
pin
AA5754 H13 • They employed FSW for
AA6082 joint to the weld of
AA6082 with AA7075 and
measured the fatigue
properties of the joint
AA6061 H13 • The rotational speed has
AA7050 significant effect on tensile
strength
(continued)
714 M. S. Dahiya et al.

Table 2 (continued)
Researchers Workpiece Tool Conclusion
Steuwer et al. [24] AA5083 H13 • Rotational speed has more
AA6082 significant effect on the
residual stresses than the
welding speed
Robe et al. [25] AA2024 H13 • They observed minimum
AA2198 micro-hardness in the
transition zone
Avinash et al. [26] AA2024 H13 • Mixing of material in the
AA7075 stir zone is uniform in
nature for both materials.
The tensile facture
occurred in the nugget
zone for all fabricated
joints
RajKumar et al. [27] AA5052 H13 • It is concluded that
AA6061 micro-structural properties
are correlated with
mechanical properties of
the joint
Moradi et al. [28] AA2024 H13 • They employed FSW for
AA6061 joining dissimilar alloys,
i.e. AA2046 and AA6061,
and observed that
efficiency of joint is
satisfactory
• It is concluded that
advancing side texture
intensity decreased,
whereas retreating side
intensity increased than the
initial sheets
Moradi et al. [29] AA2024 H13 • They observed surface
AA6061 defects on FSW joint of
AA2024 and AA6061
• The joint efficient is found
to be satisfactory
Park et al. [30] AA6111 H13 • Shoulder diameter has
AA5023 significant effect on the
mechanical and
metallurgical properties of
the joint. This is attributed
towards the change in heat
input due to change in
diameter of the tool
shoulder
(continued)
A Critical Review on Friction Stir Welding … 715

Table 2 (continued)
Researchers Workpiece Tool Conclusion
Paik [31] AA5083 H13 • The objective of the
AA5383 present study has been to
obtain test database on
mechanical properties of
friction stir welded
aluminium alloys with the
focus on 5083 and 5383
alloys
• The test database
developed in the present
study will be very useful
for the design and building
of aluminium ship
structures fabricated by
friction stir welding

Table 3 Thermal modelling

Researchers Workpiece Tool Conclusion
Bayazid et al. [32] 6063-T6 H13 • The weld characteristics
7075-T6 depend upon the heat
generation during the
process
Kumbhar et al. [33] AA5052 HSS • Improper mixing of
AA6061 material takes place in the
nugget zone
Palanive et al. [34] AA6351 HCHCr • They concluded that feed
AA5083 rate has significant effect
on mixing of material in
the nugget zone
Hamed [35] AA7075 H13 • Heat generation depends
AA5086 upon the thermal
diffusivity, tool geometry
and process parameters of
FSW. AA5086 side grains
are coarse in nature than
the AA7075 side
Ilangovan et al. [36] AA5086 HSS • They concluded that
AA6061 threaded pin profile
produces higher strength
than the taper pin profiled
owing to proper mixing of
material
• Onion rings are observed
on the macrostructure of
the threaded pin profile
joint weld
(continued)
716 M. S. Dahiya et al.

Table 3 (continued)
Researchers Workpiece Tool Conclusion
Aval [37] AA7075 H13 • Heat generation has
AA6082 significant effect on
tensile residual stress
• The grain size on the
AA7075 side is fine as
compared to AA6082
Khodir and Shibayanagi AA2024 SKD61 • Enhancement in welding
[38] AA7075 speed caused in the
formation of kissing bond
and pores in the weld
joint. This is mainly due
to improper mixing of
material in the nugget
zone
Shen et al. [39] AA6022 H13 • Tool plunge depth has
AA7075 significant effect on the
void formation in the
nugget zone
Khan et al. [40] AA2219 AA HCS • They observed fine
7475 equiaxed grain in the stir
zone. This is attributed
towards dynamic
recrystallization in the stir
zone. A maximum
hardness of 162 HV is
obtained in the stir zone of
dissimilar alloys
Pabandi et al. [41] AA2024 H13 • The joint efficient is found
AA6061 to be 26% less than that of
the similar fabricated joint
• It is observed that heat
treatment enhanced the
mechanical and
metallurgical properties of
dissimilar aluminium
alloys as compared to
simple FSW
Kumar et al. [42] AA2014 H13 • The nugget zone has fine
AA6061 equiaxed grain as
compared to base metal
due to dynamic
recrystallization
• It is concluded that with
increase in rotational
speed the hardness of
nugget zone decreases due
to dislocation of
strengthening particles
with increase in
temperature
(continued)
A Critical Review on Friction Stir Welding … 717

Table 3 (continued)
Researchers Workpiece Tool Conclusion
Kumar [43] AA3003 H13 • It is observed that weld
AA6082 speed enhances the tensile
strength, whereas
rotational speed decreases
the tensile strength. This
is attributed towards the
heat generation during the
process
Barbini et al. [44] AA2024 H13 • The SZ size is considered
AA7050 an important parameter to
qualitatively define the
value of the weldments

4 Conclusion

In the current study, an attempt has been made on different aspects of FSW of dissim-
ilar aluminium alloys. The major findings related to FSW of dissimilar aluminium
alloys are listed below:
It is evident that FSW process parameters—tool rotation rate, traverse speed,
spindle tilt angle—influence the mechanical and metallurgical behaviour of joints
and hence are crucial to produce sound- and defect-free weld.
According to the available literature, most of the research work is focused on
friction stir welding of aluminium, copper and magnesium and their alloys. Friction
stir welding of dissimilar aluminium alloys, dissimilar metals and composites, etc.,
is having huge scope for future research.
The tribological, corrosional and surface topographical behaviour of FS welded
dissimilar aluminium alloys is not elaborately discussed in the literature.
No proper guideline in terms of mathematical/theoretical model of process per-
formance parameters of FSW is available for selecting input parameters to obtain
the desired output.
Thermal modelling of FSW of dissimilar alloys is also not elaborately discussed
in the literature.

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