Development of Internal Channels on AA6061-T6 Alloy using Friction Stir Channeling Process

Abstract

Friction Stir Channeling (FSC) is an innovative approach that enables the fabrication of heat exchangers in a single step by effectively managing defects and material flow during production. This is achieved by generating incessant and stable internal channels in a metallic plate. The welding and rotation speeds, the tool pin profile and the clearance are some of the variables that affect how channels emerge during FSC. The clearance value and its connections to process characteristics, such as pin diameter are examined in this study. In the AA6061-T6 plate, the channels are made using FSC. Welding speeds of 2, 2.5 and 3 mm/s were used as process parameters, along with tool rotation speeds of 900 and 1200 rpm. To perform this, a unique tool is employed, one with helical threads at the pin and a small, sharp conical section at the tip. There are three different pin diameters available for the tool: 6, 8, 10 and 12 mm. Through experimental analysis, the maximum permitted clearance value for different tool pin sizes and process factors is determined. The internal channel features of the AA6061-T6 plate can be analysed by optical microscope and scanning electron microscopy techniques.