Abstract

Aluminium alloy plays a vital role in major engineering industries due to its high strength to weight ratio. Friction stir welding is a well-established technique to weld aluminium for more than three decades. The objective of the work is to introduce the filler materials (Mg & Cr) between the joints during welding to improve the joint strength and corrosion resistance property. The tool rotational speed, welding speed, plunge depth, center distance between the filler holes, and powder mixing ratio are considered as major parameters. The tensile strength test and microstructure evaluations are done. The best result was gained with the process parameters combination of 1000 rpm tool rotational speed, 120 mm min−1 welding speed, 0.15 mm plunge depth, center distance between the filler holes 2 mm, and powder mixing ratio 95 Mg and 5 Cr.