COMPARATIVE STUDY OF DISSIMILAR WELDINGS OF AA6061 AND AA2024 ALUMINUM ALLOYS BY FSW AND GTAW

In this research weldability of aa6061 and aa2024 aluminum alloys by gtaw and fsw was studied. friction stir welding (fsw) and gas tungsten arc welding (gtaw) of aa6061 and aa2024 aluminum alloys were carried out with sheet thickness for both alloys was 3 mm. the process parameters used for fsw were 950 rpm tool rotational speed with feeding rate of 50 mm/min. gas tungsten arc welding of aa6061and aa2024 aluminum alloys was carried out using er5356 filler rod to avoid the hot cracking and liquidation in the weld. comparative study of the joint strength and the microstructure examination showed that the heat affected zone in aa6061 has minimum hardness and strength due to the formation of dark bands of al-mg si eutectic. the joint failure occurred in heat affected zone for both fsw and gtaw 2 welded samples. results showed that by using titanium in the filler rod as an alloying addition solve the problem of hot and liquidation cracking and also it refine the grain structure of the weldments. results also showed that aa6061 and aa2024 aluminum alloys are weldable by gtaw welding using er5356 filler metal and 80 % more joint strength than that of the fsw welded joint can be achieved.