Abstract
Aluminium alloy 6082-T6 plays a vital role in the fabrication of lightweight structures, especially for the manufacturing of artillery, defense vehicles, and aircraft. Aluminium alloy 6082-T6 is a well-known structural alloy having a high strength-to-weight ratio and favorable corrosion resistance properties in extreme environments. In this study, three friction stir welding (FSW) process parameters (spindle speed, weld speed, and shoulder penetration), two geometrical tool parameters to precisely describe the pin profile, and the shoulder profile were considered at five levels. Optimization was conducted using the Taguchi experimental design method, and FSW experiments were conducted in a conventional milling machine. The parameters were optimized to maximize the tensile strength for various plate thicknesses. The number of tool pin polygon edges determines the corresponding welding pulses. The results show that 105-110 pulses/s is an optimal value to achieve a high-quality, defect-free weld. Key words: Friction stir welding, Aluminium alloy, Welding pulses, Taguchi, Microstructure
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