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Process optimization in the self-reacting friction stir welding of aluminum 6061-T6

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Abstract

Self-reacting friction stir welding (SR-FSW), also called bobbin-tool friction stir welding (BT-FSW), is a solid state welding process similar to friction stir welding (FSW) except that the tool has two opposing shoulders instead of the shoulder and a backing plate found in FSW. The tool configuration results in greater heat input and a symmetrical weld macrostructure. A significant amount of information has been published in the literature concerning traditional FSW while little has been published about SR-FSW. An optimization experiment was performed using a factorial design to evaluate the effect of process parameters on the weld temperature, surface and internal quality, and mechanical properties of self-reacting friction stir welded aluminum alloy 6061-T6 butt joints. The parameters evaluated were tool rotational speed, traverse speed, and tool plunge force. A correlation between weld temperature, defect formation (specifically galling and void formation), and mechanical properties was found. Optimum parameters were determined for the welding of 8-mm-thick 6061-T6 plate.

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Acknowledgments

The authors gratefully acknowledge the support of this research provided by the Materials and Processes Branch at NASA Johnson Space Center and Jacobs ESCG.

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Authors and Affiliations

  1. Mechanical Engineering, University of Texas of the Permian Basin, 4901 E. University, Odessa, TX, 79762, USA

    Luis Trueba Jr

  2. Department of Metallurgical and Materials Engineering, The University of Texas at El Paso, 500 W. University Ave, El Paso, TX, 79968, USA

    Monica A. Torres

  3. Materials and Processes Branch, NASA Johnson Space Center, Houston, TX, 77058, USA

    Lucie B. Johannes & Daniel Rybicki

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  1. Luis Trueba Jr
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  2. Monica A. Torres
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  3. Lucie B. Johannes
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Correspondence to Luis Trueba Jr.

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Trueba, L., Torres, M.A., Johannes, L.B. et al. Process optimization in the self-reacting friction stir welding of aluminum 6061-T6. Int J Mater Form 11, 559–570 (2018). https://doi.org/10.1007/s12289-017-1365-4

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  • DOI: https://doi.org/10.1007/s12289-017-1365-4

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