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Effect of Rotational Speed on Mechanical, Microstructure, and Residual Stress Behaviour of AA6061-T6 Alloy Joints through Friction Stir Welding

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Abstract

In the present work, the behaviour of an AA6061-T6 alloy joint through friction stir welding was studied comprehensively under a set of processing parameters so as to establish a better microstructure-strength relationship in the joint. In-depth investigations have been done on intermetallic compounds and their phases using SEM, XRD, optical microscopy, and EDS, and thereby on the mechanical properties of the welded joint through tensile, hardness, and residual stress. The results revealed the evolution of grain boundaries and the existence of second-phase particles such as Mg2Si, MgZn2, MgCu2, and Al2CuMg. Moreover, using a rotational speed of 800 rpm results in enhanced hardness, tensile strength, and flexural strength. The highest and lowest tensile strengths of 198 and 171 MPa correspond to 800 and 600 rpm, respectively. The grain size distribution in the weld zone is 76.94, 0.83 and 36.82 µm for 600, 800, and 1000 rpm, respectively. Flexural strength was improved for the 800-rpm case and reached a maximum of 380 MPa. The lowest residual stress was found for an 800-rpm sample with tensile and compressive nature of stresses. Ductile fracture behaviour was obtained for tensile samples obtained at 600 and 800 rpm, whereas in the case of 1000 rpm, brittle fracture behaviour was seen.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Mizoram, Aizawl, 796012, India

    Virendra Pratap Singh & Basil Kuriachen

  2. Department of Mechanical Engineering, IES College of Technology, Bhopal, 462044, India

    Virendra Pratap Singh & Rajan Kumar

  3. Department of Mechanical Engineering, Delhi Technological University, Delhi, 110042, India

    Ashish Kumar

  4. Department of Mechanical Engineering, Galgotias College of Engineering and Technology, Greater Noida, 201310, India

    Ashish Kumar

  5. Department of Basic Sciences, IITM, IES University, Bhopal, 462044, India

    Anchit Modi

  6. Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, PA, 15213, USA

    Deepak Kumar

  7. Department of Mechanical Engineering, National Institute of Technology, Silchar, Assam, 788010, India

    Vinyas Mahesh

  8. Department of Engineering, City, University of London, London, UK

    Vinyas Mahesh

  9. Department of Mechanical Engineering, National Institute of Technology Calicut, Kerala, 673601, India

    Basil Kuriachen

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This invited article is part of a special topical issue of the Journal of Materials Engineering and Performance on Residual Stress Analysis: Measurement, Effects, and Control. The issue was organised by Rajan Bhambroo, Tenneco, Inc.; Lesley Frame, University of Connecticut; Andrew Payzant, Oak Ridge National Laboratory; and James Pineault, Proto Manufacturing on behalf of the ASM Residual Stress Technical Committee.

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Singh, V.P., Kumar, A., Kumar, R. et al. Effect of Rotational Speed on Mechanical, Microstructure, and Residual Stress Behaviour of AA6061-T6 Alloy Joints through Friction Stir Welding. J. of Materi Eng and Perform 33, 3706–3721 (2024). https://doi.org/10.1007/s11665-023-08527-8

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