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Friction stir welding (FSW) is a solid state welding technology specially used for joining non ferrous alloys like aluminium-alloys, magnesium alloy etc. FSW have various advantages over conventional welding method like low distortion of material, lower loss of alloying materials, high strength of joint, energy efficient, environment friendly, and versatile. The present studies aimed to understand microstructural changes and associated mechanical properties of the joints produced by using FSW. In this work aluminium alloy Al6061-T6 and Al5052 sheets of thickness 3mm were used for joining. Parameters changed for joining were tool rotational speed, traverse speed and tool geometry with conical pin and hexagonal pin. These process parameters were optimized using design of experiment technique. The welded joints were tested for tensile properties and impact toughness. Metallographic observations of joints were carried out using optical microscopy; scanning electron microscopy.

Friction stir spot welding (FSSW) is a recent solid state welding technology. This welding technique is energy efficient, environment friendly, and versatile. FSSW is a novel derivative of Friction-Stir Welding (FSW) which is proving to be a better alternative to Resistance Spot Welding (RSW). In this work FSSW of aluminium alloy 6061-T6 and mild steel sheets of thickness 1.5 mm was evaluated using circular pin tool. Tool rotation speed, plunge depth and dwell time were varied to determine the effect of individual process parameter on lap shear separation load. Process parameters were optimized by using Taguchi technique. The optimum values for processing parameters were obtained as 2800 rpm rotational speed, 0.9 mm plunge depth and 8 sec dwell time. Maximum lap shear load of about 2250N was obtained. Joint interface is very clean no inter metallic compound is observed at the Al/Fe interface.