Parameter optimization of friction stir welding for AA5052 and AA6061

Friction Stir Welding process is widely being used for joining aluminium alloys for aerospace, marine, automotive and many other applications of commercial importance. In this study, the experiments have been conducted on vertical milling machine (model 3KS) on AA 5052 and AA 6061. The tool used for FSW process is of cylindrical shape of H13 high speed steel (HSS) material. From the experiment work it is concluded that the process parameters tool pin profile (cylindrical), rotational speed (1200 rpm) and welding speed (55, 34 and 22 mm/min) which are taken into consideration affects the mechanical properties of the welding joint. In this study there are two output variables are calculated which are Rockwell hardness, tensile strength. Friction Stir welding (FSW) is a fairly recent technique that utilizes a non-consumable rotating welding tool to generate frictional heat and plastic deformation at the welding location, thereby affecting the formation of a joint while the material is in the solid state. The principal advantages of FSW, being a solid-state process, are low distortion, absence of melt-related defects and high joint strength, even in those alloys that are considered non-weld able by conventional techniques. The result for the tensile strength shows that there is a significant amount of effect of tool rotational speed on the welded joint and their mechanical properties. The high tool rotation speed results in improved tensile strength of the welded joint.