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Effect of tool rotation and welding speed on microstructural and mechanical properties of dissimilar AA6061-T6 and AA5083-H12 joint in friction stir welding

  • Nishant , Sanjay Kumar Jha and Prashant Prakash ORCID logo EMAIL logo
Published/Copyright: January 3, 2025
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International Journal of Materials Research
From the journal International Journal of Materials Research Volume 115 Issue 11-12

Abstract

The study investigates joining AA6061-T6 and AA5083-H12 aluminum alloys, each 6 mm thick, in a butt joint. It aims to analyze the impact of varying input parameters on the microstructural and mechanical properties of the joints. Three tool rotation speeds (900, 1,120, 1,400 rpm) and welding speeds (40, 63, 80 mm min−1) are examined. Temperature in the weld zone correlates with tool rotation speed positively and welding speed inversely. Initially, the average grain size in the stir zone decreases with increasing tool rotation (900–1,120 rpm) and welding speed (40–63 mm min−1), then increases with further increments (1,400 rpm, 80 mm min−1). Tensile strength increases by 7 % from 900 to 1,120 rpm but decreases by 19 % at 1,400 rpm. Similarly, it rises by 14 % from 40 to 63 mm min−1, then decreases by 6 % at 80 mm min−1. Optimal mechanical properties occur at 1,120 rpm and 63 mm min−1, with ductile mode failure identified in joints with higher efficiency.

Keywords: Friction stir welding; Tool rotation speed; Welding speed; Temperature generation; Mechanical properties
Corresponding author: Prashant Prakash, Department of Production and Industrial Engineering, Birla Institute of Technology, Mesra, Ranchi, Jharkhand 835215, India, E-mail:

Acknowledgments

The authors gratefully acknowledge the department of Production and Industrial Engineering Birla Institute of Technology, Mesra, Ranchi, India.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interest: The authors state no conflict of interest.

  6. Research funding: None declared.

  7. Data availability: The data that support the findings of this study are available in the manuscript. Missing data, if any, that support the findings of this study are available from the corresponding author, upon reasonable request.

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Received: 2024-02-15
Accepted: 2024-11-12
Published Online: 2025-01-03
Published in Print: 2024-11-26

© 2024 Walter de Gruyter GmbH, Berlin/Boston

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https://doi.org/10.1515/ijmr-2024-0071
Keywords for this article
Friction stir welding; Tool rotation speed; Welding speed; Temperature generation; Mechanical properties

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  1. Frontmatter
  2. Editorial
  3. 5th International Conference on Processing and Characterization of Materials 2023 (ICPCM 2023)
  4. Original Papers
  5. Experimental studies on coal mine over-burden incorporated concrete as a sustainable substitute for fine aggregate in concrete construction
  6. A complex impedance spectroscopy study on PVDF/PANI/CoFe2O4 composites
  7. Optimizing electrical properties and efficiency of copper-doped CdS and CdTe solar cells through advanced ETL and HTL integration: a comprehensive experimental and numerical study
  8. Synthesis and characterization of hydroxyapatite from Ariidea fish bone as reinforcement material for (chios mastic gum: papyrus vaccine pollen) bio composite bony scaffold
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  10. From raw materials to functional material: synthesis and piezoelectric characterization of PIN–PT binary relaxor material
  11. Effect of ball milling on bulk MoS2 and the development of Al–MoS2 nanocomposites by powder metallurgy route
  12. Effect of beeswax on the physico-mechanical properties of poly (butylene adipate terephthalate)/poly lactic acid blend films
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  25. Ultrasonic metal welding of Al/Cu joints with Ni coating: parametric effects on joint performance and microstructural modifications
  26. News
  27. DGM – Deutsche Gesellschaft für Materialkunde
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