300
M. A. M. N. Lotpy et al.
tool, i.e. analysis of variance (ANOVA) via Minitab 19. As a result, the optimum
parameters were 910 rpm of rotational speed, rectangular pin profile and stepped joint
of edge preparation, with the minimum height of deformation at 542.25 µm. The pin
profiles were the major factor that can affect the output with a 62.38% of contribution.
The future works will be continued until the elimination of the requirement of inner
mandrel or backing plate in the use of FSW process can be achieved.
Keywords Self-support friction stir welding · AA6063 · Pipe · Deformation ·
Taguchi method
28.1 Introduction
Friction stir welding (FSW) was discovered and established in 1991 by The Welding
Institute (TWI) in Cambridge, United Kingdom. FSW utilizes the high-speed rotation friction method to join material. The joint can be produced below the melting
temperature without the use of any filler wire. This method is suitable for joining a
material that is difficult to weld such as aluminium. This new method has a variety of
excellent advantages that have already been used for various industrial applications
such as trains, ships, automobiles and civil engineering structures for aluminium
alloys [1].
According to Akbari et al. [2], most of the previous FSW research concentrated
on the lap or butt welding of flat surface plates, and only a very small number of
investigations investigated the FSW process method for joining pipes. FSW pipes
cannot be joined by standard milling machines. The development of special fixtures
is one of the most difficult tasks for welding pipes by the FSW process. In addition,
in this weld configuration, due to a small radius of curvature, the contact between the
tool and the workpiece differs from the configuration of the butted plate, resulting
in a distinctive temperature history and, consequently, a different microstructure and
mechanical properties. Figure 28.1 shows the cross view of the schematic process.
Chen et al. [3] had studied the FSW of small-diameter AA3003 and pure Cu
pipes. They used a special welding device that is very different from the one used
for the FSW of lap or butt of flat plates. They established the distinctive history of
temperature due to heat accumulation as a significant feature of small-scale FSW
pipes. In addition, the mechanical properties of welding, including tensile strength,
ductility and hardness, change accordingly along the welding line. Lammlein et al.
[4] stated that the FSW of a small-diameter pipe gave high tensile strength and sound
internal and superficial appearance.
FSW is a friction welding variant that produces welding between two or more
materials by heating the material displacement caused by the rotational tool which
transverses the weld joint. The AA6063 aluminium also has a very good welding
characteristic and can be used in temperature ranges from 500 °F to a maximum of
950 °F of hot work. The FSW joining process occurred below the melting point,
M. A. M. N. Lotpy et al.
tool, i.e. analysis of variance (ANOVA) via Minitab 19. As a result, the optimum
parameters were 910 rpm of rotational speed, rectangular pin profile and stepped joint
of edge preparation, with the minimum height of deformation at 542.25 µm. The pin
profiles were the major factor that can affect the output with a 62.38% of contribution.
The future works will be continued until the elimination of the requirement of inner
mandrel or backing plate in the use of FSW process can be achieved.
Keywords Self-support friction stir welding · AA6063 · Pipe · Deformation ·
Taguchi method
28.1 Introduction
Friction stir welding (FSW) was discovered and established in 1991 by The Welding
Institute (TWI) in Cambridge, United Kingdom. FSW utilizes the high-speed rotation friction method to join material. The joint can be produced below the melting
temperature without the use of any filler wire. This method is suitable for joining a
material that is difficult to weld such as aluminium. This new method has a variety of
excellent advantages that have already been used for various industrial applications
such as trains, ships, automobiles and civil engineering structures for aluminium
alloys [1].
According to Akbari et al. [2], most of the previous FSW research concentrated
on the lap or butt welding of flat surface plates, and only a very small number of
investigations investigated the FSW process method for joining pipes. FSW pipes
cannot be joined by standard milling machines. The development of special fixtures
is one of the most difficult tasks for welding pipes by the FSW process. In addition,
in this weld configuration, due to a small radius of curvature, the contact between the
tool and the workpiece differs from the configuration of the butted plate, resulting
in a distinctive temperature history and, consequently, a different microstructure and
mechanical properties. Figure 28.1 shows the cross view of the schematic process.
Chen et al. [3] had studied the FSW of small-diameter AA3003 and pure Cu
pipes. They used a special welding device that is very different from the one used
for the FSW of lap or butt of flat plates. They established the distinctive history of
temperature due to heat accumulation as a significant feature of small-scale FSW
pipes. In addition, the mechanical properties of welding, including tensile strength,
ductility and hardness, change accordingly along the welding line. Lammlein et al.
[4] stated that the FSW of a small-diameter pipe gave high tensile strength and sound
internal and superficial appearance.
FSW is a friction welding variant that produces welding between two or more
materials by heating the material displacement caused by the rotational tool which
transverses the weld joint. The AA6063 aluminium also has a very good welding
characteristic and can be used in temperature ranges from 500 °F to a maximum of
950 °F of hot work. The FSW joining process occurred below the melting point,