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:	en
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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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
building	UTHM Library
collection	Institutional Repository
content_provider	Universiti Tun Hussein Onn Malaysia
content_source	UTHM Institutional Repository
continent	Asia
country	Malaysia
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
id	my.uthm.eprints-12414
institution	Universiti Tun Hussein Onn Malaysia
language	en
publishDate	2024
publisher	Mdpi
record_format	eprints
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
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)
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_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_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_sort	enhancing mechanical characteristics of 6061-t6 with 5083-h111 aluminum alloy dissimilar weldments: a new pin tool design for friction stir welding (fsw)
topic	TS Manufactures
url	http://eprints.uthm.edu.my/12414/1/J17881_bfdc1afb888680d64c3baec396d1f741.pdf http://eprints.uthm.edu.my/12414/ https://doi.org/10.3390/met14050534
url_provider	http://eprints.uthm.edu.my/

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

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