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Abstract
Friction welding of high strength aluminium alloys was considered in the current study. The mechanism of bond formation in dissimilar alloy welding was compared to similar alloy welding. The differences in flow properties between two different alloys of aluminium lead to uneven deformation behaviour while welding. Since flow behaviour directly affects bond formation and strength, it is important to understand its behaviour. Rods of aluminium alloys AA 2024 and AA 6061 were welded to themselves and to each other denoting similar and dissimilar weld systems. Burn-off length, which is one of the important parameters in friction welding was varied in steps to see how it affects the bond formation. The flash geometry of the welds was observed to interpret the flow differences. Reasons for variations in bond formation were discussed with the help of fracture surfaces.