Optimization of Friction-Stir Welding of 6061-T6 Aluminum Alloy

Abstract

In this work, two simple but effective strategies were proposed to optimize friction-stir welding of 6061-T6 aluminum alloy. The first one involved an optimization of welding variables to provide a combination of a relatively high welding temperature and the shortest possible thermal cycle during friction-stir welding. This inhibited precipitation coarsening in the heat-affected zone and resulted in considerable residual stress. Accordingly, the produced welds exhibited excellent strength characteristics under static and cyclic loading conditions. The second method was based on the application of the standard postweld T6 tempering. To avoid the abnormal grain growth, which usually occurs during solutionizing of aluminum frictionstir welds, a prestrain rolling was employed prior to the material tempering. This promoted an activation of recrystallization processes during subsequent heat treatment, thus suppressing the abnormal grain growth.

Relationship between welding conditions, abnormal grain growth and mechanical performance in friction-stir welded 6061-T6 aluminum alloy

“…S1). Further microstructural details have been described elsewhere [57]. This material condition was denoted as base material throughout the manuscript.…”

Microstructure-strength relationship in friction-stir welded 6061-T6 aluminum alloy

“…S2c) which presumably originated from solidification process. Further microstructural details have been described elsewhere [40].…”

Experimental and parametric analysis of friction stir welding on AA 8011-H14 using multi-objective Taguchi-based grey relational analysis for structural applications

“…Self-reacting friction stir welded joints exhibited comparable microstructural characteristics and zones to those generated using the conventional FSW method [20]. Owing to the inherently elevated temperatures associated with the FSW process, it commonly entails intricate precipitation phenomena in heat-treatable aluminum alloys [21]. It is revealed that FSW exhibits a host of advantages when compared with other fusion welding processes because of lower heat input it does not take the metal to a molten state.…”