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The study aimed to optimise friction stir welding parameters to maximise the tensile strength, microhardness, and microstructure quality of dissimilar AA6061-T6 and AA7075-T6 alloy joints.

August 14, 2026Open Access

Optimisation of Friction Stir Welding Parameters for Dissimilar Aluminium Alloys AA6061-T6 and AA7075-T6: Effect of Tool Pin Profile, Rotation Speed, and Feed Rate on Joint Strength, Microhardness, and Microstructure

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PBP. P. Bhise

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Implication

Experimental investigation demonstrates optimal weld strength and microhardness in AA6061-T6 and AA7075-T6 joints, indicating tool geometry dominates joint efficiency.

Key Points

The study aimed to optimise friction stir welding parameters to maximise the tensile strength, microhardness, and microstructure quality of dissimilar AA6061-T6 and AA7075-T6 alloy joints.
Employed a Taguchi L16 orthogonal array testing four parameters: tool rotation speed (600–1400 rpm), feed rate (40–60 mm/min), tool pin profile (cylindrical, tapered, threaded taper), and axial force (4–6 kN).
Evaluated ultimate tensile strength, Vickers microhardness across the weld zone, and joint efficiency relative to the base AA6061-T6 alloy using Signal-to-Noise ratio analysis and ANOVA.
ANOVA identified tool pin profile as the most significant contributor to tensile strength (38.4%), followed by rotation speed (26.2%) and feed rate (22.8%).
Optimal parameters (threaded taper pin, 1000 rpm, 60 mm/min, 5 kN axial force) achieved an ultimate tensile strength of 218 MPa, 70.3% joint efficiency, and maximum nugget zone hardness of 126 HV.
Dynamic recrystallisation refined the nugget zone to a fine, equiaxed grain size of 4.2 µm, compared to 28.4 µm in AA6061-T6 and 12.6 µm in AA7075-T6 base metals.

Cite This Study

P. P. Bhise (2026) studied this question.

synapsesocial.com/papers/6a7ee587b70b84ec8b914748 https://doi.org/10.5281/zenodo.21902896

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Implication

Experimental investigation demonstrates optimal weld strength and microhardness in AA6061-T6 and AA7075-T6 joints, indicating tool geometry dominates joint efficiency.

Optimisation of Friction Stir Welding Parameters for Dissimilar Aluminium Alloys AA6061-T6 and AA7075-T6: Effect of Tool Pin Profile, Rotation Speed, and Feed Rate on Joint Strength, Microhardness, and Microstructure

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Cite This Study

Optimisation of Friction Stir Welding Parameters for Dissimilar Aluminium Alloys AA6061-T6 and AA7075-T6: Effect of Tool Pin Profile, Rotation Speed, and Feed Rate on Joint Strength, Microhardness, and Microstructure

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