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The joining of dissimilar 6mm thickness plates of AA6082 & AA5083 was carried out using friction stir welding (FSW) technique. The process parameters are optimized using Taguchi L9 orthogonal design of experiments. Where the rotational speed (600, 900, 1200 rpm), travel speed (60, 90, 120 mm/min), and tilt angle (0, 1, 2 • ) were the parameters taken into consideration. The optimum process parameters were determined with the reference to tensile strength, yield stress, elongation of the joint. Friction stir welding of aluminium alloys has gained popularity in manufacturing industries such as ship building, aircraft production, railways and automotive. Effect of process parameter on tensile properties, microstructure, and hardness distribution of the welded joints were investigated.

Metallic foams with controlled porosity are an emerging class of ultra-lightweight materials that are receiving increased attraction in automobile, military and other commercial applications. Metal foams exhibit high stiffness to weight and strength to weight ratios, and thus offer potential weight savings. They also have the ability to absorb high amounts of energy during compressive deformation for efficient crashworthiness. In the present work, closed cell aluminium metallic foams were produced through liquid state processing by using calcium as viscosity modifier and titanium hydride as blowing agent. The porosity content of the foam was 88 %. The pores are differently sized and uniformly distributed. The cell wall microstructure was studied using optical microscope. The compressive response of the foam was studied at different percentage of deformation using uni-axial compression testing machine.

The joining of similar and dissimilar AA2014, AA6068 and AA7075 aluminium plates of 6mm thickness was carried out by friction stir welding (FSW) technique. FSW of Aluminium to Aluminium has caught significant consideration from assembling industries, such as Shipbuilding, Automotive, Railway and Aircraft generation. Here, the chosen process parameters are tilt angle (2º), tool rotation speed (900rpm) and transverse feed of (80mm/min) at constant axial force 2kN. An attempt was made to join the similar and dissimilar aluminium plate of 6 mm thickness with a conical tapered tool profile. Then, the effect of welding speed on microstructures, hardness distribution and tensile properties of the welded similar and dissimilar joints AA2014, AA6068 and AA7075 were investigated.

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