Scholarlink

<p>This study systematically investigates the effect of key parameters of the friction stir welding process on the mechanical performance and weld quality of AA 6063 aluminum alloy joints, with emphasis on tool rotational speed (800-1200&#xa0;rpm), welding speed (20-30&#xa0;mm/min), and tool geometry (namely tapered threaded, square cylindrical, and hexagonal profiles). A Box–Behnken experimental design combined with response surface methodology was employed to evaluate the interaction of these parameters and to develop a highly reliable predictive model for tensile strength, achieving a low prediction error of 1.49%. The analysis identified that the tapered threaded tool operating at 1000&#xa0;rpm and 20&#xa0;mm/min was the optimal combination, resulting in superior tensile strength, hardness, impact strength, and weld quality. Enhanced surface integrity under this condition was confirmed through 3D surface roughness analysis, indicating stable material flow and effective consolidation in the weld zone. Detailed SEM fractography of tensile-tested specimens revealed predominantly ductile fracture features characterized by fine, equiaxed dimples, especially for the optimized tapered threaded tool, reflecting improved plastic deformation and joint integrity. Furthermore, x-ray radiographic inspection showed minimal internal defects, demonstrating that appropriate control of thermal and mechanical inputs through optimized process parameters and tool design is essential for producing defect-free, high-performance friction stir welded AA 6063 joints.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Investigation on the Effect of Process Parameters on Mechanical Properties of AA 6063 Friction Stir Welded Alloy

  • 期刊论文

  • 发表日期：

    2026年4月30日

查看全文
  • Pramod Ramakrishnan,
  • M. R. Radhakrishna Panicker,
  • N. Biju

摘要

This study systematically investigates the effect of key parameters of the friction stir welding process on the mechanical performance and weld quality of AA 6063 aluminum alloy joints, with emphasis on tool rotational speed (800-1200 rpm), welding speed (20-30 mm/min), and tool geometry (namely tapered threaded, square cylindrical, and hexagonal profiles). A Box–Behnken experimental design combined with response surface methodology was employed to evaluate the interaction of these parameters and to develop a highly reliable predictive model for tensile strength, achieving a low prediction error of 1.49%. The analysis identified that the tapered threaded tool operating at 1000 rpm and 20 mm/min was the optimal combination, resulting in superior tensile strength, hardness, impact strength, and weld quality. Enhanced surface integrity under this condition was confirmed through 3D surface roughness analysis, indicating stable material flow and effective consolidation in the weld zone. Detailed SEM fractography of tensile-tested specimens revealed predominantly ductile fracture features characterized by fine, equiaxed dimples, especially for the optimized tapered threaded tool, reflecting improved plastic deformation and joint integrity. Furthermore, x-ray radiographic inspection showed minimal internal defects, demonstrating that appropriate control of thermal and mechanical inputs through optimized process parameters and tool design is essential for producing defect-free, high-performance friction stir welded AA 6063 joints.