Investigation of Weldability in Friction Stir Welding of Aluminum Alloys AA5754 and AA2024

This study examined the weldability of AA5754 and AA2024 aluminum alloys using the friction stir welding (FSW). Through systematic analysis of welding parameters such as rotational and traverse speeds, we have identified configurations to improve the mechanical properties and efficiency of the welds significantly. The optimal parameters, specifically a rotational speed of 1200 rpm combined with a traverse speed of 45 mm/min, were found to yield the best outcomes. The welding efficiency achieved was 54% for the AA5754 alloy and 26% for the AA2024 alloy, with a combined alloy efficiency of 47% when welding dissimilar materials. The study has conclusively demonstrated that appropriate parameter selection is crucial for maximizing weld strength and minimizing defects such as voids and cracks. This research contributes to the understanding of the FSW applicability in joining dissimilar aluminum alloys, emphasizing the importance of parameter optimization to achieve desirable mechanical characteristics and weld integrity.