The influence of tool shoulder size and plate position on the characteristics of friction stir welded different aluminum alloys

Abstract

ABSTRACT Welding is a main manufacturing method for fabricating various engineering components. Fusion welding techniques encounter solidification associated problems while joining light weight structures. Friction stir welding is a solid state welding technique that is developed to address these shortcomings. As the superior conductive properties of AA6101-T6 and AA1350 aluminum alloys, they are frequently utilized in electrical industries. The goal of this study is to examine how the plate position and tool shoulder diameter (D) affect the qualities of these dissimilar Al-alloys joints. It is discovered that plate positioning is the most influential welding parameter in determining the tensile properties of weldment. Furthermore, the joint fabricated with AA6101-T6 as an advancing side material and a 15 mm tool shoulder diameter produces sufficient weld reaction temperature, better plastic flow and tensile properties. However, the joint fabricated with AA1350 as an advancing side material and 12 mm tool shoulder diameter generates inadequate reaction temperature, poor plasticization, and tensile properties. The formation of precipitates as well as the interface layer at the weld nugget is greatly dominated by the tool shoulder size, which affects the wear properties of weldment.