Effect of Joint Configurations on Joint Strength of Different Thickness AA6061-T6 Friction Stir Welded Blank

Abstract

AbstractThis paper presents a comparative study of the mechanical properties and microstructures of three friction stir welded joint configurations, namely square butt (SB), scarf (SC), and double butt lap (DBL) of the aluminium alloy 6061-T6. The experiment was conducted on two aluminium plates of different thicknesses, 2.0 mm on the advancing side and 1.5 mm on the retreating side, at constant welding parameters such as welding speed, spindle rotation, tool tilt angle, and tool profile. The study compared the joints at different rolling angles, i.e., 00/00, 900/900, 00/900, and 900/00. Tensile tests were conducted on the joints, and the ultimate tensile strength (UTS) was found to be 6%–11% higher in the DBL joint configuration compared to the SC and SB joint configurations. The Vickers hardness values of the SC and DBL joints were also found to be higher than those of the SB joint configuration. The formation of the "S" line was observed to influence the tensile test, hardness, and grain size, which in turn are determined by the shape of the faying surface.Keywords: friction stir weldingjoint configurationdifferent thicknessDisclaimerAs a service to authors and researchers we are providing this version of an accepted manuscript (AM). Copyediting, typesetting, and review of the resulting proofs will be undertaken on this manuscript before final publication of the Version of Record (VoR). During production and pre-press, errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal relate to these versions also. Additional informationFundingThe first author would like to acknowledge the Public Service Department of Malaysia for the scholarship support under the HLP program and School of Mechanical Engineering for the facilities provided.