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Aluminum alloys like AA6061-T651 are widely favored in automotive and manufacturing for their lightweight, strength, corrosion resistance, and thermal conductivity. Friction Stir Welding (FSW), a solid-state method, joins aluminum without filler metal, yielding joints akin to the base metal. FSW advantages include reduced spatter, porosity prevention, and cost-effectiveness. This study investigates FSW variables—tool rotation speed (765-3022 rpm) and welding speed (24-90 mm/min)—and their impact on AA6061-T651 weld macro structure. CNC milling experiments optimize parameters for stronger joints and fewer defects. Analysis reveals significant effects of tool rotation speed, shoulder and tool tilt angles, and welding speed on weld characteristics, notably Thermo-Mechanically Affected Zone (TMAZ) and Heat Affected Zone (HAZ) sizes. Precise FSW parameter adjustment is crucial for optimal weld quality, defect minimization (e.g., porosity), and meeting strength and structural integrity requirements in specific applications.
Prayugo et al. (Wed,) studied this question.