In this paper, the effect of tool tilt angle on heat generation and forging force for 1050 aluminum plates, welded by friction stir butt welding, were investigated. Usage of the welding tool with and without pin made it possible to elucidate the particularly reactions of the pin and shoulder on tilt angle variation. For this purpose, tool tilt angle was varied from 0⁰ to 3⁰ under other constant parameters, such as tool geometry and of tool traverse-rotation speed ratio. For the estimation shoulder work pieces interaction the Reynolds lubricant film theory equations were used. The results indicate that the tilt angle is an effective factor on material forging and heat generation behind the pin in the Advancing Side (AS). Recorded peak temperatures were varied from 312 °C to 442 °C in the weld centre.

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Friction stir welding (FSW) has become an important application in modern industries. Friction stir welding is a widely used solid state joining process for soft materials such as aluminum alloys as it avoids/minimizes common problems of fusion welding processes, i.e. distortion, porosity, solidification and liquation cracking etc. Improper selection of parameters such as welding speed, rotational speed, forge force, back plate material etc. affects the weld quality. Thermal boundary condition at the bottom of the work pieces to be joined is important in determining the result of weld quality and its properties, for a given alloy type, tool geometry and selected process parameters (welding speed, rotational speed etc), These thermal boundary conditions are governed by the back plate material used. By using backing plates made out of materials with widely varying thermal diffusivity this work seeks to elucidate the effects of the root side thermal boundary condition on weld process variables and resulting joint properties. Welds were made in 5-mm-thick AMг5 (AA 5056) using siliceous coating, stainless steel, mild steel, and aluminum as backing plate (BP) material. Effects of backing plate material on the tensile strength and elongation were obtained for a particular case.

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