Friction stir welding is a high potential technology for joining similar and dissimilar aluminum materials, utilized extensively in aerospace and automotive industrial applications to eradicate the problems like hot cracking, porosity, element loss, etc. due to the fusion welding process. This Research addresses the joining of two dissimilar materials of AA 5754 – H32 and AA 8090T6511 – Al-Li and their mechanical properties analysis with the effects of friction stir welding process parameters like tool rotational speed, welding speed and axial load on weld nugget zone formation quality. The significant roles of different tool pin profiles are also emphasized. A mathematical modeling equation was formed by using regression analysis to optimize the process parameter and found the best tool pin profile for defect-free weld nugget zone and higher tensile and hardness properties. This research also portrays the contribution of various pin profiles and each process parameter on the ultimate tensile strength by response surface methodology. The results indicate that the defect-free weld joints are observed with 1800 r/min of rotational speed, welding speed of 15 mm min⁻¹ and 8.5 kN of axial load with hexagonal pin profile.

搅拌摩擦焊是一种用于连接相似和不同铝材料的高潜力技术，广泛用于航空航天和汽车工业应用，以消除由于熔焊过程引起的热裂纹、孔隙率、元素损失等问题。本研究解决了 AA 5754 – H32 和 AA 8090T6511 – Al-Li 两种不同材料的连接及其机械性能分析，以及搅拌摩擦焊接工艺参数（如工具转速、焊接速度和轴向载荷）对焊接熔核区形成的影响质量。还强调了不同工具销轮廓的重要作用。通过回归分析形成数学建模方程，优化工艺参数，找到无缺陷焊核区和更高拉伸和硬度性能的最佳工具销轮廓。该研究还通过响应面方法描绘了各种销钉轮廓和每个工艺参数对极限抗拉强度的贡献。结果表明，在转速为 1800 r/min、焊接速度为 15 mm min 的条件下观察到无缺陷的焊缝^-1和 8.5 kN 的轴向载荷，六角销轮廓。