Optimizing the Parameters for Friction Stir Welding of an Aluminium Alloy

A novel slip factor accounted for thermal model is being used to predict the temperature with time and the effect of welding and rotations on heat input for weld length peak-temperature of the friction stir welding process. Material used in this study is aluminium alloy of AA6061 grade which is used in aerospace applications. For various rotations and weld velocities, friction stir welding experiments were conducted on aluminium alloy plates. The plates were fixed with thermocouples at different locations from weld centerline to measure the temperatures during the welding process. The temperature with time and locations predicted by the model along the transverse direction are closely matching with the experimental results. The heat input for unit length of weld and peak-temperature increases as rotation increases and decreases as weld velocity increases. The energy required for welding for length is minimum at the combination of lower rotation and higher weld velocity in the defect-free zone.