Optimization Parameter of Friction Stir Welding Process for Aluminum Alloy 6061-T6

Abstract

The friction stir welding (FSW) process is a solid-state joining invented via the Welding Institute in 1991 at a great rate emerging as an application by fusion welding for joining different alloys. The wrought aluminum alloy 6061 is heat treatable and possesses a high corrosion resistance. This alloy has been used in various applications, like arenas, gymnasiums and trains bodies. Aluminum alloy 6061 cannot be easily welded by the conventional fusion welding process because of the cracks that make the mechanical welding joint very weak. In friction stir welding (FSW), many parameters affect its welding process. In the present research, three distinct rotation speeds (900,1120,1400 r.p.m), three distinct welding speeds (20,30,40 mm/min) and a cylindrical profile tool and tilt angle of (1.5°) was studied. Result manifested that the welding at room temperature for parent metal at a (1400 r.p.m) rotational speed and a (30 mm/min) welding speed gave the best result of the ultimate tensile strength (171 N/mm2.