This paper discusses the various joining methods with faying surface modifications used to join AA6063 and AISI304L dissimilar alloys by Rotary Friction Welding (RFW) process at different welding conditions mainly with friction pressure (FP), upset pressure (UP) and friction time (FT). This paper also studies the tensile behavior of the welded joints. The fabricated dissimilar joints were tested using universal testing machine against tensile load, and the mechanical properties of all 30 nos. of weld joints like elongation (%), strength coefficient (K), strain hardening exponent (n), strain hardening rate (TS/YS ratio), shear strength, etc. were calculated from the tensile testing results and plotted here with a standard error bar. Hollomon’s equation is considered here to study the stress and strain hardening relation and Von Mises yield criterion is considered for shear and yield stress correlation. Total elongation is also calculated from the initial and final length obtained during the tensile test. Since fracture ductility of the joints depends on the stress, strain, ‘K’ and ‘n’ values, it is important to study these mechanical properties and how the tensile results can be used for their estimation is detailed in this paper. The faying surfaces influence the mechanical properties as well.
