The aim of this research is to study the effects of single-pass/ double-pass techniques on friction stir welding of aluminium. Two pieces of AA1100 with a thickness of 6.0 mm were friction stir welded using a CNC milling machine at rotational speeds of 1400 rpm, 1600 rpm and 1800 rpm respectively for single-pass and double-pass. Microstructure observations of the welded area were studied using an optical microscope. The specimens were tested by using a tensile test and Vickers hardness test to evaluate their mechanical properties. The results indicated that, at low rotational speed, defects such as 'surface lack of fill' and tunnels in the welded area contributed to a decrease in mechanical properties. Welded specimens using double-pass techniques show increasing values of tensile strength and hardness. From this investigation it is found that the best parameters of FSW welded aluminium AA1100 plate were those using double-pass techniques that produce mechanically sound joints with a hardness of 56.38 HV and 108 MPa strength at 1800 rpm compared to the single-pass technique.
The present study focuses on the effects of material position and tool rotational speed on the tensile strength of dissimilar AA7071 and AA6061 welded aluminum alloys with a thickness of 2.0 mm in using a conventional milling machine. Ten joints were produced by varying tool rotational speeds and by changing the fixed position of the material on the advancing and retreating sides. The results show that the maximum tensile strength of 207 MPa was achieved for Sample E when AA6061 aluminum alloys were placed on the advancing side at a rotational speed of 1000 rpm with seamless surface appearance and no inner defect across the weld area, while the lowest tensile strength of 160 MPa was obtained for Sample F when AA6061 was placed on the retreating side with severe tunnel defects across the weld area contributing to crack propagation. Thus, in dissimilar welding, weaker materials should be placed on the advancing side to trigger heat from the tool rotation and smooth the material flow formation in the stirred zone.
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