Welding high-strength, age-hardenable aluminium alloys from the 2XXX and 7XXX series poses challenges when using fusion-based welding processes. Common issues such as hydrogen porosity, hot cracking, stress corrosion cracking, and solidification cracking can lead to a reduction in mechanical properties due to the loss of strengthening precipitates and alloying elements. Consequently, friction stir welding (FSW) has emerged as a promising solid-state welding technique for joining dissimilar aluminium alloys and composites, particularly in aerospace applications where a combination of strength, corrosion resistance, and other desirable properties is required. This study investigates the FSW of dissimilar aluminium alloys, specifically AA2014 and a hybrid metal-matrix composite of AA7075 reinforced with silicon carbide and graphite particles. The microstructural and mechanical properties of the welded joints were characterized, revealing an average grain size of 2.39 mu m +/- 1.2 in the stir zone (SZ). A high angle grain boundary volume fraction of 47.25% was observed in the SZ, compared to 2.01% in the AA7075 composite and 15.03% in the AA2014 base metal. The presence of shear textures and the distribution of cube, S, and H textures indicate a homogeneous mixing of the base materials and a high shear strain rate during welding. The hardness of the SZ increased by 13%, and the ultimate tensile strength, yield strength, and elongation of the joint were measured at 251 MPa, 183 MPa, and 6.44%, respectively. The flexural strength of the joints improved significantly, with the CW13 sample showing a 67% increase compared to CW1. The dissimilar joint CW13, welded at 12.5 mm min(-1), achieved a maximum joint efficiency of 95%.
