A COMPREHENSIVE EXPERIMENTAL STUDY ON THE FRICTION STIR WELDING PROCESS FOR JOINING AA6063 ALUMINIUM ALLOY

Authors

  • Regala Aneela Department of Physics, B V Raju Institute of Technology, Narsapur, Medak, Telangana, 502313, India
  • Ajay D Diwate Department of Mechanical Engineering, TSSM's Bhivarabai Sawant College of Engineering and Research Narhe, Pune, Maharshtra, 411041, India.
  • Ummar Pasha Shaik Department of Physics, Anurag Engineering College, Ananthagiri, Suryapet, Telangana, 508206, India
  • Shridhar Rajan Bhasale Endurance Technologies Limited, Waluj, Chhatrapati Sambhajinagar, Maharashtra 431136, India
  • Pramod Purandare Department of Mechanical Engineering, Marathwada Mitramandal’s College of Engineering, Karvenagar, Maharashtra, 411052, India
  • Vikas Bhimrao Pawa Department of Applied Science, Bharati Vidyapeeth College of Engineering Navi Mumbai, 400614, India
  • Chandrashekhar Ramtirhkar Department of Mechanical Engineering, Vishwakarma Institute of Information Technology, Kondhwa Budruk, Maharashtra 411048, Indi
  • Rahul Shivaji Yadav Department of Mechanical Engineering, Marathwada Mitramandal’s College of Engineering, Karvenagar, Maharashtra, 411052, India

DOI:

https://doi.org/10.11113/aej.v16.24618

Keywords:

Universal Testing Machine, Friction Stir Welding, Microstructure, Welding Plates, AA6063

Abstract

Despite the widespread use of welding in manufacturing and structural applications, inconsistencies in weld quality remain a significant challenge. Factors such as material flow and heat distribution during the welding process play a critical role in determining the integrity of the weld. This study focuses on using Friction Stir Welding (FSW) to join AA6063 aluminum alloy using a milling machine with a vertical spindle attachment. Four different trials, labeled T1, T2, T3, and T4, are conducted, each with varying welding speeds and tool rotational speeds to explore the impact of these parameters on the weld quality. The tools used in these trials have different threading: M12×1.75 and M8×1, and each has a distinct shoulder diameter. This variation in tool design affects the surface area in contact with the workpiece during welding, which in turn influences heat generation and material flow. The primary goal of these experiments is to assess the weld quality based on several key factors, such as the presence of fractures, porosity, and blow holes, as well as the effect of heat on the grain structure in the welded material, particularly in the heat-affected zone (HAZ). The study demonstrates the milling machine's capability for performing FSW on aluminum alloys, an important aspect for industrial applications where precision and integrity are crucial. The welded joints undergo tensile testing according to ASTM E407-2007 standards. The results show a maximum weld penetration of 8.71 mm, with no cracks or blow holes observed in the joints, indicating high-quality welds. Additionally, the heat-affected zone is visible, reflecting the thermal effects on the material due to the welding process. Overall, the study provides valuable insights into optimizing FSW parameters and highlights the effectiveness of using a milling machine for aluminum alloy welding.

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Published

2026-03-01

Issue

Vol. 16 No. 1: March 2026

Section

Articles