Fixtures are robust mechanical clamping devices used for precise machining. It is used to securely locate, hold and support the workpiece in a specific position during the machining operation. Fixtures for micro-friction stir welding (µFSW) are basically used to hold workpieces during welding operations. Using a conventional milling machine for µFSW operation with a simplified milling fixture is less expensive. This paper presents a simplified design of an adjustable milling fixture for µFSW, in which plates of different thicknesses can be welded. The low-cost fixture is designed using AutoCAD software, considering the transverse and lateral movement of tools and workpieces. Later, the developed milling fixture setup was tested in actual µFSW operations using the pinless tool of H13 material and 8 mm diameter. During operation, 0.8 mm thick Al6061-T6 plates were placed in lap and butt configuration and successful welding joints were obtained at a constant tool spinning speed of 2000 rpm and traverse speed of 100 mm/min. The maximum strength of the joint found 274.40 MPa for butt configuration and 201.25 MPa in lap configuration, which is about 87.34% and 64.10% of the parent material’s strength (314.19 MPa).
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