Effect of Tool Profile, Rotational Speeds and Welding Speed on Mechanical Properties and Weld Quality of Friction Stir Welded 6063-T4 Aluminum Alloy

Abstract

This chapter is focused on friction stir welding of aluminum alloy 6063-T4 which is very useful in shipbuilding, aerospace, robotics and personal computers. In friction stir welding, rotational speed, tool feed rate and tool pin profile plays an important role to get desired weld quality for the softer materials like AA6063-T4. In this experimental research work, friction stir welding is used for a butt joint five mm thick IS: AA6063-T4 using different tool pin profile (cylindrical, threaded cylindrical and triangular), rotational speeds (600, 800 and 1000 rpm) and welding speed (40, 60 and 80 mm/min) and their effect on tensile strength, hardness and weld quality is studied. The results have been evaluated and compared with that original specimen. The data collected during experiments and analyzed using statistical tool. Regression analysis is carried by taking ultimate tensile strength as dependent variable, and rotational speed and welding speed as independent variable. The results show that rotational speed is contributing more as compared to the welding speed. A t-test statistical analysis shows the significant variation in tensile strength and hardness because of selected tool profiles.  Also, another t-test analysis shows that there is significant variation in weld quality due to selected variables. The weld joint quality in cylindrical pin tool and threaded cylindrical pin tool are better than that of thr triangular pin tool in all the cases.