This work describes the effect of newly introduced faying surfaces on the microstructure and the mechanical properties of dissimilar weld joints of AA6063 and AISI304L alloys that are fabricated through the rotary friction welding process (RFW). The experiments were done as six different experimental methods (‘A’ to ‘F’) at 1300 rpm rotation, 18 MPa friction pressure (FP), 24 MPa upset pressure (UP) and 5 s friction time (FT) with the faying surfaces of hemispherical bowl and thread of 1 mm pitch on the weld specimens. The fabricated joints and the weld zones were characterized by macro and microstudy, energy dispersive X-ray spectroscopy (EDS) spectrums, tensile properties, Vickers microhardness, impact toughness and fractography. The results showed that these faying surface modifications strengthen the bonding between the weld specimens and influences the performance of the joints. The hemispherical bowl showed better results than the threaded surfaces. Axial shortenings were within the acceptable limit in the range of 20–27 mm. Macro and microstructural studies showed the defect-free weld joints and the strong bonding between AA6063 and AISI304L alloys. The hemispherical faying surface on AISI304L alloy formed a U-shaped weld interface (WI) in the dissimilar joints. EDS proved the formation of the Fe–Al intermetallic and the element ‘O’ at weld zone. The joint efficiency for all the methods was around ≥100%. Maximum tensile strength was recorded as 238 MPa for method F. The threaded surface showed good hardness property nearby WI, and method A yielded maximum impact toughness for the joint.

这项工作描述了新引入的接合面对通过旋转摩擦焊接工艺 (RFW) 制造的 AA6063 和 AISI304L 合金的异种焊接接头的微观结构和机械性能的影响。在 1300 rpm 转速、18 MPa 摩擦压力 (FP)、24 MPa 镦粗压力 (UP) 和 5 s 摩擦时间 (FT) 下，以六种不同的实验方法（“A”到“F”）与接合面进行实验焊缝试样上的半球形碗和 1 毫米节距的螺纹。通过宏观和微观研究、能量色散 X 射线光谱 (EDS) 光谱、拉伸性能、维氏显微硬度、冲击韧性和断口分析来表征制造的接头和焊接区。结果表明，这些搭接表面改性加强了焊缝试样之间的结合并影响了接头的性能。半球形碗表现出比螺纹表面更好的结果。轴向缩短在 20-27 毫米范围内的可接受范围内。宏观和微观结构研究表明 AA6063 和 AISI304L 合金之间无缺陷的焊接接头和牢固的结合。AISI304L 合金上的半球形接合面在异种接头中形成 U 形焊接界面 (WI)。EDS 证明了在焊接区形成了 Fe-Al 金属间化合物和元素“O”。所有方法的联合效率约为≥100%。方法 F 的最大拉伸强度记录为 238 MPa。螺纹表面在 WI 附近显示出良好的硬度特性，