Abstract
In the present study, friction stir welding (FSW) of butt and scarf joints of Al 6063-T6 were investigated. Five different tool pin profiles (cylindrical, tapered cylindrical, square, triangular, and hexagonal) were applied for performing welding. Scarf joint, being a new joint configuration, was used and effect of pin profiles was investigated on this type of joint configuration. The effect of pin profiles on microstructure, micro-hardness, impact and tensile properties of friction stir welded Al 6063-T6 was investigated. Scanning electron and optical microscopy were employed to characterize the different zones of welded joints. A thorough discussion on correlation between mechanical properties and microstructure has been made. In addition, the formation of various defects during the FSW was discussed with the help of fractography of the fractured surfaces.
Highlights
Aluminum alloy has been widely acknowledged in fabrication of lightweight structures especially for aviation, automobile and the entire transportation sector as it has high strength to weight ratio, corrosion resistance and good formability
Defects that form during the course of action were reported and discussed, and feasible recommendations have been made to prevent their formation
Summary
Aluminum alloy has been widely acknowledged in fabrication of lightweight structures especially for aviation, automobile and the entire transportation sector as it has high strength to weight ratio, corrosion resistance and good formability. For joining certain classes of aluminum alloys (e.g., age hardenable alloys), a new hot shear welding technique known as Friction Stir Welding (FSW), proved a great success [1,2,3]. It is evident from the research available that flaws like porosity and hot cracking are not found in FSW [4]. This process is energy efficient and environmentally friendly too [6]. The welding process operates by governing the amount of frictional heat generated between the rotating tool and the workpiece being welded, through a set of process parameters like tool rotation speed, plunge depth, welding speed, etc., in such a way so as to Metals 2018, 8, 74; doi:10.3390/met8010074 www.mdpi.com/journal/metals
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