To improve the performance and effectiveness of cost, constructing lightweight structure is the important factor for automobile, naval and aerospace industries. AA5052 and AA6101-T6 aluminium alloys are widely applied in transport industries, due to their lightweight and high strength and hence, joining of these two are unavoidable. Friction stir welding is an unconventional welding method, which is developed for constructing lightweight structures. This work describes the detailed study of friction stir welded dissimilar AA5052 and AA6101-T6 alloys. AA5052 and AA6101-T6 plates are welded with rotation rates of 765–1400 rpm and offset distances at advancing side of 0–2 mm. For this purpose, four levels of welding parameters based on Taguchi L16 orthogonal array are chosen. To determine the optimum combinational levels and identify the effect of above-mentioned parameters on tensile and wear properties, Signal to Noise ratio and ANOVA respectively are used. From the results, it is observed that the combination of 1 mm offset distance at advancing side and 1400 rpm rotating speed produces better tensile and wear properties, which is due to high heat generation, sufficient flow of materials and balanced precipitation and strain hardening effects. On the other hand, the combination of 2 mm tool offset at advancing side and 765 rpm rotational rate exhibits poor properties, which is associated with low heat input, defects formation, precipitate coarsening and lesser strain hardening effects.

Natural fibre reinforcement is used in important sectors such as medical, aerospace, automobile, and many other fields. Many articles have reported that natural fibre has the potential to replace synthetic fibres. Natural fibre reinforcement has given good results as a brake friction material. It has already been proven that asbestos causes lung cancer and mesothelioma in brakes. Many people died from the effects of asbestos. According to the World Health Organization’s trending brake report, this material leads to serious health issues. This work is going on for the replacement of these materials. Mulberry fibre is a unique material, and PAN fibre is combined with mulberry fibre and used as a brake reinforcement material to replace Kevlar fibre. The brake pads were fabricated with the various wt% of mulberry fibres and PAN fibre [3–12%] with an equal ratio and aramid fibre [3–6%] in the hydraulic hind brake moulding machine. The mechanical, chemical, physical, tribological, and thermal properties were evaluated. MF-2 [6 wt%] mulberry-PAN-fibre-based brake pad composites have shown better results for ultimate shear strength and proof stress, tensile strength, compressive strength, and impact energy.