OPTIMIZATION OF FRICTION STIR WELDING PARAMETERS FOR SIMILAR AND DISSIMILAR ALUMINUM ALLOYS AA5083-H111 AND AA7075-T651
Azarias Mavropoulos, Ioannis Tsikrikonis
Pages: 54-63
Received: 26 Jun 2025
Published: 27 Dec 2025
DOI: 10.62991/MMT1996718152
Views: 189
Downloads: 18
Abstract: In recent years, the increasing demand in the industry for lightweight and durable materials has driven research into various aluminum alloys, which are relatively inexpensive and offer a high strength-to-weight ratio. Aluminum alloys are utilized across multiple sectors such as aerospace, automotive, and shipbuilding. Many applications require welding similar or dissimilar alloys, which, with conventional fusion methods, are often impossible or result in degraded weld quality. Friction Stir welding, a solid-state welding technique, is increasingly popular because it is eco-friendly, energy-efficient, and prevents common issues like solidification cracks. The goal of this work was to determine the optimal parameters for successful similar and dissimilar welds. Accordingly, three tools were designed and manufactured to perform butt welds on thin alloy plates of 5083-H111 and 7075- T651, both similar and dissimilar. The parameters were optimized, and the weld microstructure was examined using an optical microscope. Lastly, micro-hardness measurements were taken on the optimal welds.
Keywords: friction stir welding, aluminum alloys, aa5083, aa7075, welding parameters
Cite this article: Azarias Mavropoulos, Ioannis Tsikrikonis. OPTIMIZATION OF FRICTION STIR WELDING PARAMETERS FOR SIMILAR AND DISSIMILAR ALUMINUM ALLOYS AA5083-H111 AND AA7075-T651. Journal of International Scientific Publications: Materials, Methods & Technologies 19, 54-63 (2025). https://doi.org/10.62991/MMT1996718152
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