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<p>Friction stir welding (FSW) is an advanced solid-state welding technique, further enhanced by the self-reactive friction stir welding (SRFSW) process, which eliminates the need for a backing plate. This study investigates the SRFSW of AA6061-O aluminum alloy with water as a cooling medium to regulate heat input and refine the weld microstructure. The experiments were conducted using an L9 orthogonal array, with rotational speed varying from 800 to 1200&#xa0;rpm and traversal speed ranging from 60 to 100&#xa0;mm/min. Microstructural analysis revealed the formation of a fine-grained structure in the nugget zone due to the cooling effect, contributing to enhanced mechanical properties. Tensile strength evaluation indicated a weld joint efficiency exceeding 70% of the base material, with an ultimate tensile strength of 102.32&#xa0;MPa and an elongation of 22%. Fractographic analysis of the weld bead exhibited reduced ductility compared to the base material. Wear performance analysis demonstrated a significant improvement, with an 81% increase in erosion wear resistance and a 68% enhancement in sliding wear resistance. Taguchi optimization identified the optimal processing parameters for grain size, microhardness, and erosion rate at 800&#xa0;rpm rotational speed and 100&#xa0;mm/min traversal speed. ANOVA results confirmed that rotational speed is the most significant factor influencing the weld responses. This study demonstrates that cooling-assisted SRFSW is a promising approach for enhancing joint performance, offering a potential solution for industries requiring superior mechanical and tribological properties in aluminum alloy welds.</p>

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Evaluation of Mechanical, Microstructural, and Tribological Characteristics of Cooling-Assisted Self-Reactive Friction Stir-Welded AA6061 Joints

  • 期刊论文

  • 发表日期：

    2025年6月6日

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  • Vishal Bhojak,
  • Jinesh Kumar Jain,
  • M. K. Banerjee,
  • Tejendra Singh Singhal

摘要

Friction stir welding (FSW) is an advanced solid-state welding technique, further enhanced by the self-reactive friction stir welding (SRFSW) process, which eliminates the need for a backing plate. This study investigates the SRFSW of AA6061-O aluminum alloy with water as a cooling medium to regulate heat input and refine the weld microstructure. The experiments were conducted using an L9 orthogonal array, with rotational speed varying from 800 to 1200 rpm and traversal speed ranging from 60 to 100 mm/min. Microstructural analysis revealed the formation of a fine-grained structure in the nugget zone due to the cooling effect, contributing to enhanced mechanical properties. Tensile strength evaluation indicated a weld joint efficiency exceeding 70% of the base material, with an ultimate tensile strength of 102.32 MPa and an elongation of 22%. Fractographic analysis of the weld bead exhibited reduced ductility compared to the base material. Wear performance analysis demonstrated a significant improvement, with an 81% increase in erosion wear resistance and a 68% enhancement in sliding wear resistance. Taguchi optimization identified the optimal processing parameters for grain size, microhardness, and erosion rate at 800 rpm rotational speed and 100 mm/min traversal speed. ANOVA results confirmed that rotational speed is the most significant factor influencing the weld responses. This study demonstrates that cooling-assisted SRFSW is a promising approach for enhancing joint performance, offering a potential solution for industries requiring superior mechanical and tribological properties in aluminum alloy welds.