Abstract
Present work aims to achieve high welding speed during friction stir welding of lightweight battery trays in the electric vehicle industry. This study reports high-speed friction stir welding (HSFSW) up to 4.0 m min−1 in AA6063-T6 alloys. The defect-free HSFSW joints are produced by adopting aggressive material mixing, i.e. higher tool rotation and plunge force. HSFSW weld cross-section reported an unusual hardness profile of ‘U’ shape instead of ‘W’ shape in conventional FSW of AA6xxx alloys. HSFSW resulted softening of weld stir zone (∼60HV) along with HAZ (∼53HV) against the base material (BM) hardness of ∼90HV. The HSFSW at 4.0 m min−1 obtained good joint strength of 71% of the BM. Microstructure evolutions across the fractured weld cross-section are discussed using EBSD analysis.
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