296
K. Giridharan et al.
Keywords Friction stir welding (FSW) · AA6082-AA7075 alloys · Process
parameters · Tool pin profiles · Mechanical properties
1 Introduction
The innovative solid-state joining process likely named as Friction stir welding
process (FSW). This material joining technique also called an environment-friendly
process.
It was invented by the welding institute (TWI) of the United Kingdom in1991
[1]. Initially, the legend Wayne Thomas and his team members carried by similar
material joining process for this technique [1, 2]. At later in this technique was
preferred to join two similar and dissimilar alloys in different combinations. In FSW,
a non-consumable revolving tool used to fabricate weld joints with different tool
configurations such as tool shoulder diameter, pin profile, and pin diameter. The
specially designed FSW tool was inserted two metal plates and traveled along with
the weld direction at various speeds. The tool shoulder surface contact with the top
surface workpiece [3]. The FSW tool plunged into two plates at high speed and heat
generate frictional heat between the two surfaces. Simultaneously the tool moves
the specified conditions to the weld direction which results to get the weld joint.
Compared to other fusion technology, the FSW process is the most attractive ecofriendly joining technology to receive fine microstructure, absence of the weld defects
such as porosity, weld cracks, and minimum residual stresses produced in weld joints
during the material combined process. In this method, there is no use for additional
filler material and shielding process [2–4]. The tool turning speed, traveling speed,
pin profiles, and downward force is the primary process parameters are used while
joining the two alloys plate or sheets. The process parameters are involved in a major
role in the microstructural behavior of the welded materials [5].
The FSW process has specified different zones named Nugget or weld zone (NZ),
Heat Affected Zone (HFA), Thermo Mechanically Heat Affected Zone (TMAZ) and
Unaffected Parent Material Zone (UAPZ) [5]. The internal defects and stresses are
an important issue for all the types of material joining processes. But it could be
seen the minimum amount of material defects induced in the FSW joining process
because of its excellent combined characteristics [6]. The experimental arrangement
of the Friction stir welding process has illustrated in Fig. 1.
Aluminum alloys are mostly used in different applications. Because of these
aluminum alloys have good mechanical, material properties and it is future based
applications. In day by day, aluminum alloys have become progressively more
utilized in different engineering fields of applications [3–6]. The fields are automotive industry, shipbuilding, aerospace equipment manufacturing, construction, and
building, marine engineering, food packaging, production of defense-related products and several structural applications, etc. [6]. Aluminum alloys have good unique
mechanical properties named as corrosion resistance, good formability, fracture
toughness, low density, thermal and electrical conductivity. Generally, the aluminum
K. Giridharan et al.
Keywords Friction stir welding (FSW) · AA6082-AA7075 alloys · Process
parameters · Tool pin profiles · Mechanical properties
1 Introduction
The innovative solid-state joining process likely named as Friction stir welding
process (FSW). This material joining technique also called an environment-friendly
process.
It was invented by the welding institute (TWI) of the United Kingdom in1991
[1]. Initially, the legend Wayne Thomas and his team members carried by similar
material joining process for this technique [1, 2]. At later in this technique was
preferred to join two similar and dissimilar alloys in different combinations. In FSW,
a non-consumable revolving tool used to fabricate weld joints with different tool
configurations such as tool shoulder diameter, pin profile, and pin diameter. The
specially designed FSW tool was inserted two metal plates and traveled along with
the weld direction at various speeds. The tool shoulder surface contact with the top
surface workpiece [3]. The FSW tool plunged into two plates at high speed and heat
generate frictional heat between the two surfaces. Simultaneously the tool moves
the specified conditions to the weld direction which results to get the weld joint.
Compared to other fusion technology, the FSW process is the most attractive ecofriendly joining technology to receive fine microstructure, absence of the weld defects
such as porosity, weld cracks, and minimum residual stresses produced in weld joints
during the material combined process. In this method, there is no use for additional
filler material and shielding process [2–4]. The tool turning speed, traveling speed,
pin profiles, and downward force is the primary process parameters are used while
joining the two alloys plate or sheets. The process parameters are involved in a major
role in the microstructural behavior of the welded materials [5].
The FSW process has specified different zones named Nugget or weld zone (NZ),
Heat Affected Zone (HFA), Thermo Mechanically Heat Affected Zone (TMAZ) and
Unaffected Parent Material Zone (UAPZ) [5]. The internal defects and stresses are
an important issue for all the types of material joining processes. But it could be
seen the minimum amount of material defects induced in the FSW joining process
because of its excellent combined characteristics [6]. The experimental arrangement
of the Friction stir welding process has illustrated in Fig. 1.
Aluminum alloys are mostly used in different applications. Because of these
aluminum alloys have good mechanical, material properties and it is future based
applications. In day by day, aluminum alloys have become progressively more
utilized in different engineering fields of applications [3–6]. The fields are automotive industry, shipbuilding, aerospace equipment manufacturing, construction, and
building, marine engineering, food packaging, production of defense-related products and several structural applications, etc. [6]. Aluminum alloys have good unique
mechanical properties named as corrosion resistance, good formability, fracture
toughness, low density, thermal and electrical conductivity. Generally, the aluminum