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<p>This study investigates the underwater friction stir welding (UWFSW) of AA6063 aluminum pipe joints. It evaluates the effects of tool rotation speed, traverse rate, and shoulder diameter on tensile performance and corrosion behavior. A Central Composite Design (CCD) was employed to model the influence of process parameters on ultimate tensile strength (UTS), yield strength (YS), and corrosion rate (CR). The optimum tensile strength was obtained at <i>N</i> = 1800&#xa0;rpm, <i>S</i> = 10&#xa0;mm/min, and <i>D</i> = 41&#xa0;mm, while a multi-objective optimum balancing UTS, YS, and CR was identified at <i>N</i> = 1360&#xa0;rpm, <i>S</i> = 10&#xa0;mm/min, and <i>D</i> = 43&#xa0;mm, producing UTS ≈ 250&#xa0;MPa, YS ≈ 163&#xa0;MPa, and CR ≈ 0.57&#xa0;mm/yr. The novelty of this work lies in integrating process capability indices (Cp, Cpk) with ANOVA, regression modeling, and EBSD-based microstructural analysis to evaluate both process stability and the mechanistic origins of property variation. Unlike previous UWFSW studies that rely primarily on mean mechanical values or qualitative micrographs, this study quantitatively links microstructural features—grain boundary character, dynamic recrystallization fraction, and local strain (KAM)—to performance variability and capability metrics. The combined statistical–mechanistic framework establishes a reproducible parameter window for high-strength, corrosion-resistant UWFSW joints suitable for marine and pipeline applications.</p>

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Statistical Evaluation and Mechanical Performance of Underwater Friction Stir Welded Aluminum 6063 Pipe Joints

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Ibrahim Sabry,
  • Mohamed ElWakil

摘要

This study investigates the underwater friction stir welding (UWFSW) of AA6063 aluminum pipe joints. It evaluates the effects of tool rotation speed, traverse rate, and shoulder diameter on tensile performance and corrosion behavior. A Central Composite Design (CCD) was employed to model the influence of process parameters on ultimate tensile strength (UTS), yield strength (YS), and corrosion rate (CR). The optimum tensile strength was obtained at N = 1800 rpm, S = 10 mm/min, and D = 41 mm, while a multi-objective optimum balancing UTS, YS, and CR was identified at N = 1360 rpm, S = 10 mm/min, and D = 43 mm, producing UTS ≈ 250 MPa, YS ≈ 163 MPa, and CR ≈ 0.57 mm/yr. The novelty of this work lies in integrating process capability indices (Cp, Cpk) with ANOVA, regression modeling, and EBSD-based microstructural analysis to evaluate both process stability and the mechanistic origins of property variation. Unlike previous UWFSW studies that rely primarily on mean mechanical values or qualitative micrographs, this study quantitatively links microstructural features—grain boundary character, dynamic recrystallization fraction, and local strain (KAM)—to performance variability and capability metrics. The combined statistical–mechanistic framework establishes a reproducible parameter window for high-strength, corrosion-resistant UWFSW joints suitable for marine and pipeline applications.