Microstructure and mechanical properties in dissimilar rotary friction welding of aluminum AA6061-T6/AA5083-H112

The present study used rotary friction welding of dissimilar AA6061-T6/AA5083- H112 aluminum alloy rods for different rotational speeds under constant time and pressure. The research aims to understand the effect of the rotational speeds parameter on the heat cycle, microstructure, and mechanical properties of RFW joints. Several experiments were done, i.e., temperature measurement, tensile tests, macro and microstructural examinations, microhardness, scanning electron microscope, and fatigue tests. The research findings indicate that the higher rotational speed generates higher temperature, narrow DRZ area, wider TMAZ/HAZ region, and longer burn-off length. Otherwise, insufficient heat produces welding defects. The RFW process causes a decrease in both static and fatigue strength where fracture location occurs in the AA6061-T6 base metal side. © The Author(s) 2025