Abstract
The study investigates the effectiveness of a novel joint configuration, the double-butt-lap (DBL), in friction stir welding (FSW) to join 6-mm-thick AA 6061-T6 plates. Four welds, including a simple square butt (SSB) configuration and three DBL variations (with UB to LB ratios of 1:2, 1:1, and 2:1), were executed. Using consistent parameters, the investigation evaluates the force distribution, macrostructure, and mechanical properties of the joints. Results show varied force profiles; spindle torque and Z-force decrease notably in DBL configurations compared to SSB, while X-force decreases overall for all DBL variations. Macrostructural analysis indicates increased weld area and finer microstructures in DBL joints. A correlation between peak temperature, grain size, and hardness highlights larger grain sizes at higher temperatures, influencing joint hardness. The DBL configuration with a 2:1 ratio exhibits the highest joint efficiency (83.76%). Fractographic analysis indicates ductile failure in all samples. Bend testing reveals increased flexural strength and bend angles in two DBL-configured joints compared to SSB. The results indicate that using a 2:1 ratio for joining 6-mm AA6061-T6 plates through FSW is viable, providing valuable insights into enhancing mechanical properties by optimizing joint geometry.
| Original language | English |
|---|---|
| Pages (from-to) | 1089-1101 |
| Number of pages | 13 |
| Journal | Welding in the World, Le Soudage Dans Le Monde |
| Volume | 68 |
| Issue number | 5 |
| DOIs | |
| Publication status | Published - May 2024 |
| Externally published | Yes |
Keywords
- Aluminum alloy
- Friction stir welding
- Joint configuration
- Mechanical property
- Microstructure
ASJC Scopus subject areas
- Mechanics of Materials
- Mechanical Engineering
- Metals and Alloys