Effect of Modified Pin Profile and Process Parameters on the Friction Stir Welding of Aluminum Alloy 6061-T6

Abstract

This work deals with the effect of a new “bolt-head” pin profile on the friction stir welding performance of the aluminum alloy 6061-T6, compared to traditional pin profiles. Friction stir welding parameters such as the tool rotation speed and the welding speed were investigated together with the different pin profiles; the results show that the new “bolt-head” pin profile leads to better mechanical properties of welded specimens. The pin profiles used in this work were the straight square (SS), straight hexagon (SH), taper cylindrical (TC), and the straight hexagon “bolt-head” (SHBH). It was found that the last pin profile improves the material flow behavior and the uniform distribution of plastic deformation and reduces the formation of macroscopic defects on the welded zone. Mechanical tensile tests on welded specimens were performed to determine the tensile strength: the specimens welded with the SHBH pin profile have shown the highest mechanical properties. An approach is presented for material flow on this aluminum alloy using the SHBH pin profile, which is related to the improvement on the resulting mechanical properties.

Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates

“…were focused on the tool geometry in FSW process. Juarez et al (Verduzco Ju arez et al, 2016) have studied the effect on FSW of aluminium alloys Al6061 with modified tool pin, confirmed that the straight hexagon bolthead kind of tool pin provides a good amount of flow of material during welding. However, Fujji et al (Fujii et al, 2006) found that while performing FSW with aluminium alloys the tool shape is not significant to achieve better mechanical properties at lower rotational speed (600 rpm).…”

Experimental Investigation of Dry and Cryogenic Friction Stir Welding of AA7075 Aluminium Alloy

“…Careful thermal insulation is done with help of foam (polymer in nature) in order to prevent being affected by external heat during the transfer. e nozzle is availed to point the fluid towards the friction stir welding zone [12,[14][15][16][17][18][20][21][22]]. An AWM720P1 flow sensor is availed to ensure a constant volume flow rate for liquid nitrogen at 1 bar pressure atmospheric pressure which is 1.977 litres/minute, by taking the total head loss in consideration, elevation point of the FSW setup, and having initial velocity and exit pressure to be zero.…”

“…Another major factor of oil coolants is in the area of formation of fumes and gases which when exposed in the welding environment causes long-term health deteriorations [13]. So, given the scenario, dry FSW was concluded to be a cleaner operation along with being cost effective in nature [5,14].…”

Effect of Pre and Post Weld Heat Treatment on the Mechanical Properties of Friction Stir Welded AA6061-T6 Joint

“…journal.ump.edu.my/ijame ◄ investigation were kept constant at rotation speed of 1000 rpm, feed speed of 90 mm/min, penetration speed of 9 mm/min, and holding time of 10 seconds. The last parameters were selected to reduce the defects of welding [21].…”