LAUSR

Abstract In the present investigation, dissimilar friction welding between AA6063-T6 and SS 304L materials of pipe joint configuration with an outer diameter of 88.90 mm and a wall thickness of 5.4 mm was performed. Four different experimental conditions were varied based on visual inspection after each weld. The welded pipe joints were evaluated by vacuum leak detection, thermal shock test, pneumatic pressure test, tensile test, optical and scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray diffractions, X-ray elemental mapping, and hardness measurements. The results revealed that friction welded Al-SS bimetallic pipes sustained ultra-high vacuum pressure and cryogenic working environments without leak detection. Al-SS friction welded pipe resulted in high tensile strength with 72% of joint efficiency as compared to AA6063-T6 base material. Microstructure variations were observed significant towards AA6063-T6 material close to the Al-SS interface. The intermetallic compound of Fe3Al phase was identified with a reaction layer between Al-SS joints with varying thickness of 1.1 µm to 2.0 µm.