Abstract
The semi-solid-metal 6063 aluminum alloy was developed for the automotive industry. The objective of this research was to optimize parameters in friction stir welding process that can provide the highest tensile strength. The ANOVA factorial design was used to analyze rotation speed, welding speed, and tool geometry at different factor levels of experimentation. The results showed that the optimized tensile strength was 120.7 MPa from the cylindrical tool, rotation speed was from 1300 to 2100 rpm, and welding speed less than 75 mm/min in the coefficient of determination R2 was 95.09%, as can be considered from the regression equation. The examination of the stir-zone and thermal mechanical affected zone using SEM and EDX showed that the new recrystallization of the microstructure causes fine grain in the stir-zone, coarse grain in advancing-side thermal mechanical affected zone, and equiaxed grain in the retracting-side thermal-mechanical affect zone. The intermetallic compounds of β-Al5FeSi phase transformation phase were formed to three types, i.e., β″-Al5Fe, Mg2Si, and Al8Fe2Si phase were observed. Moreover, in the stir-zone and thermal-mechanical-affected zone, defects were found such as flash defects, void or cavity defects, crack defects, lack of penetration defects, tunnel defects, kissing bond defects, and dendrite formation defects affecting weldability.
Highlights
The semi-solid-metal (SSM) 6063 is Al-Mg aluminum alloy materials that were developed for new techniques for forming castings in a semi-solid state, which application used in the automotive and other industries
The shape of the tool pin affects the quality of joint substantiate; Li et al [13] investigated bobbin tool geometry of friction stir welding process (FSWp) of ZK60-T5 magnesium alloy that affects the weld quality, and the result showed that the taper angle pin of 10◦ reduced the travel force and bobbin tool geometry welding speed to 600 mm/min for resulting in optimized welding quality observed
The optimization of dissimilar FSWp between the 6N01 and 7N01 was high-quality joint strength, when the estimated fatigue of FSWp joints tested found that a good relationship between fatigue strength and tensile strength is σω (R = −1) = 0.53 σB was obtained reported by Sillapasa et al [18]
Summary
The semi-solid-metal (SSM) 6063 is Al-Mg aluminum alloy materials that were developed for new techniques for forming castings in a semi-solid state, which application used in the automotive and other industries. The main idea of this study was to find optimized parameters for FSWp of SSM 6063 aluminum alloy, such as rotation speed, welding speed, and different shapes of tools that influence welding quality. In this experiment, the result of tensile strength was analyzed with a statistical engineering program, with the GFFD model, to develop equations to forecast tensile strength optimization of welded joints observed.
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