ABSTRACT
This chapter covers a very special topic of Friction Stir Welding (FSW) of dissimilar aluminum alloys. It discusses sequential discussions on the need and applications of dissimilar joining, its challenges, and a status report on how this is being practiced. The chapter highlights major issues involved with the dissimilar material welding emphasized and challenges of FSW of dissimilar material welding. Welding of dissimilar metal has always been a challenging task during fusion welding. Different aluminum alloys contain specific alloying elements wherein the concentration of these elements varies widely leading to large variation in properties specially the melting point and thermal conductivity. The common techniques used for joining dissimilar aluminum alloys are mechanical fastening, welding, soldering, brazing, adhesive bonding, etc. Manufacturing and transportation industries have shown interest in joining of dissimilar aluminum alloys, but problems associated with difference in properties of both the materials make this difficult.
