Tensile Properties of Friction Stir Welded AA6061-T6 Aluminum Alloy with Different Tool Geometries and Process Parameters

Abstract

This study analyses the influence of tool pin geometry and process parameters on the friction stir welding process using AA6061-T6 aluminum alloy. The experiments were conducted with varies tool rotational speeds, transverse speeds, and two types of tool pin geometry. Welded products then used for visual analysis in tension measurement for comparing. Results from the experimental revealed that increasing the transverse speed enhances both tensile strength and welded joints’ ductility. For the tool geometries, square pin produced higher tensile strength and joint efficiency than the taper-threaded pin. However, at higher transverse speeds, the taper-threaded pin exhibited greater elongation, which is likely attributed to enhanced helical material flow during the welding process. Factorial analysis indicated that transverse speed was the most influence factor affecting ductility, whereas the combined effects of rotational speed and transverse speed affect the joint efficiency. Results of the present research demonstrate that higher transverse speeds provide high joint efficiency and good ductility. These findings extend the practical processing window for friction stir welding of AA6061-T6 aluminum alloy and provide useful guidance for process optimization in industrial applications.