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Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)

This research addresses the escalating need for lightweight materials, such as aluminum and magnesium alloys, in the aerospace and automotive sectors. The study explores friction stir welding (FSW), a cost-efficient process known for producing high-quality joints in these materials. The experiment i...

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Main Authors: Khalafe W.H., Sheng E.L., Bin Isa M.R., Shamsudin S.B.
Other Authors: 58032960800
Format: Article
Published: Multidisciplinary Digital Publishing Institute (MDPI) 2025
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spelling my.uniten.dspace-366682025-03-03T15:43:47Z Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW) Khalafe W.H. Sheng E.L. Bin Isa M.R. Shamsudin S.B. 58032960800 58032789200 58032285700 57200084869 This research addresses the escalating need for lightweight materials, such as aluminum and magnesium alloys, in the aerospace and automotive sectors. The study explores friction stir welding (FSW), a cost-efficient process known for producing high-quality joints in these materials. The experiment involved the welding of dissimilar aluminum alloys (AA5086-H111 to AA6061-T6) using a novel pin tool design with welding parameters such as holding time, pin tool length, tool spindle speed, and linear speed fine-tuned through a design of experiment (DOE) approach. A comparative analysis of two tool designs revealed that the newly introduced design substantially improved mechanical properties, particularly tensile strengths, by 18.2% relative to its predecessor. It is noteworthy that FSW joint efficiency is 83% when using a normal tool design in comparison with 92.2% when using a new tool design at similar FSW parameters. The new tool achieved the parameter values leading to the maximum tensile strength of 317 MPa with 3 mm thickness (Th), 25 s holding time (Tt), 0.1 mm dimension (L), 1600 rpm spindle speed (SS), and 30 mm/min feed velocity (Fr). In comparison, the normal tool achieved a maximum UTS of 285 MPa, 5 mm Th, 25 s Tt, 0.3 mm L, 800 rpm SS, and 90 mm/min Fr. The new tool design, with longitudinal and circular grooves, improves heat input for plastic deformation and alloy mixing during welding. Subsequent analysis of the joint?s microstructure and microhardness shows its similarity to the original alloys. ? 2024 by the authors. Final 2025-03-03T07:43:47Z 2025-03-03T07:43:47Z 2024 Article 10.3390/met14050534 2-s2.0-85194226288 https://www.scopus.com/inward/record.uri?eid=2-s2.0-85194226288&doi=10.3390%2fmet14050534&partnerID=40&md5=846ec62e6cbce6faaa0153c3d77784fa https://irepository.uniten.edu.my/handle/123456789/36668 14 5 534 Multidisciplinary Digital Publishing Institute (MDPI) Scopus
institution Universiti Tenaga Nasional
building UNITEN Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Tenaga Nasional
content_source UNITEN Institutional Repository
url_provider http://dspace.uniten.edu.my/
description This research addresses the escalating need for lightweight materials, such as aluminum and magnesium alloys, in the aerospace and automotive sectors. The study explores friction stir welding (FSW), a cost-efficient process known for producing high-quality joints in these materials. The experiment involved the welding of dissimilar aluminum alloys (AA5086-H111 to AA6061-T6) using a novel pin tool design with welding parameters such as holding time, pin tool length, tool spindle speed, and linear speed fine-tuned through a design of experiment (DOE) approach. A comparative analysis of two tool designs revealed that the newly introduced design substantially improved mechanical properties, particularly tensile strengths, by 18.2% relative to its predecessor. It is noteworthy that FSW joint efficiency is 83% when using a normal tool design in comparison with 92.2% when using a new tool design at similar FSW parameters. The new tool achieved the parameter values leading to the maximum tensile strength of 317 MPa with 3 mm thickness (Th), 25 s holding time (Tt), 0.1 mm dimension (L), 1600 rpm spindle speed (SS), and 30 mm/min feed velocity (Fr). In comparison, the normal tool achieved a maximum UTS of 285 MPa, 5 mm Th, 25 s Tt, 0.3 mm L, 800 rpm SS, and 90 mm/min Fr. The new tool design, with longitudinal and circular grooves, improves heat input for plastic deformation and alloy mixing during welding. Subsequent analysis of the joint?s microstructure and microhardness shows its similarity to the original alloys. ? 2024 by the authors.
author2 58032960800
author_facet 58032960800
Khalafe W.H.
Sheng E.L.
Bin Isa M.R.
Shamsudin S.B.
format Article
author Khalafe W.H.
Sheng E.L.
Bin Isa M.R.
Shamsudin S.B.
spellingShingle Khalafe W.H.
Sheng E.L.
Bin Isa M.R.
Shamsudin S.B.
Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
author_sort Khalafe W.H.
title Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
title_short Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
title_full Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
title_fullStr Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
title_full_unstemmed Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
title_sort enhancing mechanical characteristics of 6061-t6 with 5083-h111 aluminum alloy dissimilar weldments: a new pin tool design for friction stir welding (fsw)
publisher Multidisciplinary Digital Publishing Institute (MDPI)
publishDate 2025
_version_ 1825816280325685248
score 13.244413

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