Priya Reddy
Independent Researcher
India
Abstract
Friction Stir Welding (FSW) has emerged as a prominent solid-state joining technique, particularly for aluminium alloys, which are extensively used in aerospace, automotive, and marine industries. This study evaluates the mechanical properties, microstructural characteristics, and process parameters influencing the quality of FSW joints in aluminium alloys. Experimental welding trials were conducted on AA6061 and AA7075 alloys with varying rotational speeds and traverse speeds. Mechanical testing and microstructural analysis were performed to assess joint strength and defect formation. Statistical analysis shows significant influence of welding parameters on tensile strength and hardness. The study confirms that optimal parameter selection improves joint integrity and performance, validating FSW as a superior joining process for aluminium alloys with enhanced metallurgical and mechanical outcomes.
Keywords
Friction Stir Welding, Aluminium Alloys, AA6061, AA7075, Mechanical Properties, Process Parameters, Microstructure
REFERENCES
- Mishra, R. S., & Ma, Z. Y. (2005). Friction stir welding and processing. Materials Science and Engineering: R: Reports, 50(1–2), 1–78. https://doi.org/10.1016/j.mser.2005.07.001
- Threadgill, P. L., Leonard, A. J., Shercliff, H. R., & Withers, P. J. (2009). Friction stir welding of aluminium alloys. International Materials Reviews, 54(2), 49–93. https://doi.org/10.1179/174328009X411136
- Rai, R., De, A., Bhadeshia, H. K. D. H., & DebRoy, T. (2011). Friction stir welding tools. Science and Technology of Welding and Joining, 16(4), 325–342. https://doi.org/10.1179/1362171811Y.0000000023
- Kumar, K., & Kailas, S. V. (2008). The role of friction stir welding tool on material flow and weld formation. Materials Science and Engineering: A, 485(1–2), 367–374. https://doi.org/10.1016/j.msea.2007.08.013
- Elangovan, K., & Balasubramanian, V. (2008). Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminium alloy. Materials & Design, 29(2), 362–373. https://doi.org/10.1016/j.matdes.2006.11.002
- Cavaliere, P., De Santis, A., Panella, F. W., & Squillace, A. (2009). Effect of welding parameters on mechanical and microstructural properties of AA6056 joints produced by friction stir welding. Journal of Materials Processing Technology, 200(1–3), 364–372. https://doi.org/10.1016/j.jmatprotec.2007.09.041
- Lee, W. B., & Yeon, Y. M., & Jung, S. B. (2004). The improvement of mechanical properties of friction-stir-welded A356 Al alloy. Materials Science and Engineering: A, 355(1–2), 154–159. https://doi.org/10.1016/j.msea.2003.09.028
- Gandra, J., Miranda, R. M., & Pereira, M. F. (2013). Friction stir welding of dissimilar aluminum alloys: A review. Materials & Design, 45, 512–521. https://doi.org/10.1016/j.matdes.2012.09.062
- Su, J. Q., Nelson, T. W., Mishra, R. S., & Mahoney, M. W. (2003). Microstructural investigation of friction stir welded 7050-T651 aluminium. Acta Materialia, 51(3), 713–729. https://doi.org/10.1016/S1359-6454(02)00449-4
- Bozkurt, Y. (2012). The optimization of friction stir welding process parameters to achieve maximum tensile strength in polyethylene sheets. Materials & Design, 35, 440–445. https://doi.org/10.1016/j.matdes.2011.09.031
