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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, Wazir Hassan, Sheng, Ewe Lay, Isa, Mohd Rashdan, Shamsudin, Shazarel
Format: Article
Language:English
Published: Mdpi 2024
Subjects:
TS Manufactures
Online Access:http://eprints.uthm.edu.my/12414/1/J17881_bfdc1afb888680d64c3baec396d1f741.pdf
http://eprints.uthm.edu.my/12414/
https://doi.org/10.3390/met14050534
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spelling my.uthm.eprints.124142025-02-20T01:40:53Z http://eprints.uthm.edu.my/12414/ Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW) Khalafe, Wazir Hassan Sheng, Ewe Lay Isa, Mohd Rashdan Shamsudin, Shazarel TS Manufactures 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. Mdpi 2024 Article PeerReviewed text en http://eprints.uthm.edu.my/12414/1/J17881_bfdc1afb888680d64c3baec396d1f741.pdf Khalafe, Wazir Hassan and Sheng, Ewe Lay and Isa, Mohd Rashdan and Shamsudin, Shazarel (2024) Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW). Metal, 14 (534). pp. 1-22. https://doi.org/10.3390/met14050534
institution Universiti Tun Hussein Onn Malaysia
building UTHM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Tun Hussein Onn Malaysia
content_source UTHM Institutional Repository
url_provider http://eprints.uthm.edu.my/
language English
topic TS Manufactures
spellingShingle TS Manufactures
Khalafe, Wazir Hassan
Sheng, Ewe Lay
Isa, Mohd Rashdan
Shamsudin, Shazarel
Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
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.
format Article
author Khalafe, Wazir Hassan
Sheng, Ewe Lay
Isa, Mohd Rashdan
Shamsudin, Shazarel
author_facet Khalafe, Wazir Hassan
Sheng, Ewe Lay
Isa, Mohd Rashdan
Shamsudin, Shazarel
author_sort Khalafe, Wazir Hassan
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 Mdpi
publishDate 2024
url http://eprints.uthm.edu.my/12414/1/J17881_bfdc1afb888680d64c3baec396d1f741.pdf
http://eprints.uthm.edu.my/12414/
https://doi.org/10.3390/met14050534
_version_ 1825163113208479744
score 13.244413

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