Consequences of Modification in Interface Angles of the Plates in Friction Stir Welding of Different Aluminium Alloys

Abstract

Because of their low weight and good strength, AA6101-T6 and AA1350 aluminium alloys are extensively utilized in the electrical and automotive industries. A number of compelling benefits of friction stir welding (FSW) include the capability to weld metals that are challenging to weld using typical welding techniques. This one is carried out in the solid-phase and as a result, weldments do not experience solidification related problems. Hence, the joining of these alloys is conducted by FSW process. The primary goal of this research is to look into the effects of angular variation between aluminium alloys at the interface region. Here, the interface angle means the angle at which end surfaces of two plates mate each other. To evaluate the properties of weldments, tensile and hardness tests, macro and microstructural analyses were conducted. When compared to various interface angles, the results showed that a 90° interface angle results in enough heat input, plastic flow of materials, dynamic recrystallization and fine grain structure which leads to a defect-free weld and better tensile (69 MPa), hardness (57.1 VHN) and wear (7.69 % weight loss) properties. Whereas 150° interface angle at retreating side yields poor tensile (46 MPa), hardness (41.3 VHN) and wear (10.40 % weight loss) properties. This is attributed with insufficient heat generation and lack of plasticization at lower portion which produces poor flow properties of materials, cracks and volume defects.