Friction Stir Welding of Aluminium Alloys and Advanced Steel for Lightweight, Sustainable Automotive and Aerospace Applications

The project focused on optimizing the process parameter window for maximum joint strength by analysing the microstructural and mechanical properties of joint.

This research focuses on friction stir welding (FSW) of dissimilar materials with different properties, such as aluminium and Advanced steel. FSW is a well-known advanced solid state welding technique suitable to join aluminium alloys and now being explored for other materials such as advanced materials, composites and polymers, etc. The FSW is widely used in automotive and aerospace applications click here to know more. The current research explores the potential of FSW in joining dissimilar alloys and its feasibility by analysing the mechanical and microstructural properties and their correlations.

Project Previews:

FSW in lap joints
Hardness distributions in weld cross-section

Skill Used

Materials Characterization: SEM, TEM, XRD, Optical Microscopy . Mechanical Characterizations: UTM, Micro-hrdenss, Nano-indentation . Instruments: FSW CNC, Abacus, AutoCad

References

2026

  1. Microstructure and Mechanical Properties of Friction Stir Welded AA6082 Aluminium Alloy and Dual-Phase 780 Steel Dissimilar Joints
    Deepak Kumar, Ranjit Bauri, and Tej Prakash
    Journal of Manufacturing Processes, 2026
    Under review
    Abs