IRACST- International Journal of Research in Management & Technology (IJRMT), ISSN: 2249-9563

Vol. 5, No.1, February 2015

Analysis of process parameters effect on

friction stir welding of aluminium 5083 and
6082
Jagtar singha, Lakshmi shankarb
ab
Department of mechanical engineering,university college of engineering,Punjabi university patiala
intermetallic compound (IMC) layer formation,
Abstract-In this study,5083-H111 and 6082-T651 which makes it a promising solution for similar
aluminum alloy plates in 6mm thickness that are material joining. Several studies have been
used, particularly for shipbuilding industry were carried out on FSW of aluminum alloy.
welded using Friction Stir Welding (FSW) method
Aluminum and aluminum alloys have
joined by butt joint with the parameters of
1250rpm and 1050rpm tool rotation,65 mm/min become increasingly used in production of
and 55mm/min welding speed and 2* tool tilt automobiles and trucks, packaging of food and
angle and with the round and rectangular tool tip beverages, construction of buildings,
shape and tool shoulder size 20mm and transmission of electricity, development of
22mm.Tensile tests results showed sufficient joint transportation infrastructures, production of
efficiencies and surprisingly high yield stress values defense and aerospace equipment, manufacture
and hardness no. by Vickers hardness test showed of machinery and tools and marine structures
hardness at welded surface is more than base metal with its unique properties such as corrosion
surface. Tensile strength and hardness of welded
resistance, thermal conductivity, electrical
area is compared within the different tool shapes
(rectangular and round), their diameter (20mm and conductivity, high strength with low density,
22mm) and rotational speed (1050rpm and fracture toughness and energy absorption
1250rpm),welding speed(55mm/min and capacity, cryogenic toughness,workability,ease
65mm/min)with base metal. of joining [welding (both solid state and
fusion),brazing , soldering, riveting, bolting] and
Keywords-friction stir welding,tensile
testing,microhardness, elongation, diameter, recyclability.5083 aluminum–magnesium alloys
rotational speed, welding speed. are strain hardenable and have excellent
corrosion resistance, toughness,weldability and
moderate strength. 6082 aluminum–magnesium–
1 INTRODUCTION
silicon alloys are heat treatable and have high
Growing concerns on energy saving and corrosion resistance, excellent extrudibility and
environmental preservations increase the demand moderate strength. Especially with their high
for lightweight vehicles. Considerable volumes corrosion resistance and moderate strength, these
of aluminium have been applied into automotive alloys are widely used in shipbuilding industry
parts in order to reach the objective of both both separately and together. Single or multiple-
weight reduction and crashworthiness full high speed ferries employ several aluminum
enhancement.However, further weight reduction alloys, and there is an increasing need to design
of 30% or more is hardly achievable with lightweight structures such as those in aircraft
exclusive dependence on the use of thinner panels and vehicle body shells. Advanced joining
aluminum sheets.Multimaterial vehicle structures technology is an integral part of the
is an efficient countermeasure against this manufacturing processes of lightweight
problem, which necessitates the development of structures. Considerable effort has been
reliable and cost-effective material joining expended to develop various joining processes
technique. One of the desired pairs is aluminum and assess their suitability for use in lightweight
alloy. Friction stir welding (FSW), which was structures.5454 as sheet and plate (along with
first developed by The Welding Institute (TWI) 6082 extruded shapes) with all-welded
in 1991, has a solid-state nature and therefore construction .Aluminum welding was once
exhibits certain advantages over traditional considered limited due to the problems
fusion welding methods. First, it can associated with welding processes such as oxide
significantly avoid solidification related removal and reduced strength in the weld and
problems, such as oxidization, shrinkage, heat affected zone (HAZ).New aluminum
porosity, and hydrogen solubility. Second, the welding techniques have been developed and
associated low heat input can effectively inhibit commercialized in significantly over the past 30
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Vol. 5, No.1, February 2015

years that solves these welding problems. FSWed AA6082-T6 aluminum alloy. He welded
Although Metal Inert Gas (MIG) and Tungsten 4 mm thick plates with 1600 rpm tool rotation
Inert Gas (TIG) welding processes were and welding speed varying 40–460 mm/min. He
developed in 1940s and used in many industries, found that welding speed had a threshold points
there were still some joint problems that reduced for grain structure, yield stress and ductility that
joint efficiency under % 50.Welding processes reversed these properties behavior to the opposite
without reaching melting temperature or change side[3]. Palanivel R et al.(2012)studied effect of
of phases in the base material.FSW also made all tool rotational speed and pin profile on
aluminum alloys weldable that were once microstructure and tensile strength of dissimilar
considered unweldable or limitedly weldable. friction stir welded AA5083-H111 and AA6351-
Further, the reduced welding temperature made T6 aluminum alloys. He used pin profiles of
joints with lower distortions and residual Straight Square, straight hexagon, straight
stresses, enabling improved fatigue performance, octagon, tapered square and tapered octagon and
new construction techniques, and making three different tool rotational speeds and found
possible the welding of very thin and very thick that straight square pin profile with 950 rpm tool
materials. Even though FSW produced joints that rotational speed yielded highest strength[4].
were metallurgically, environmentally and Moreira et al.(2009) studied to characterize
economically better than other welding mechanical and metallurgical properties of
processes, owing to the typically high forces in friction stir welded butt joints of aluminum alloy
the process, FSW was usually practiced as a fully 6061-T6 with 6082-T6.For comparison, similar
mechanized process, increasing the cost of the and dissimilar material joints made from each
equipment compared to arc welding techniques, one of the two alloys were micro structurally
while reducing the degree of operator skill examined, and micro hardness, tensile and
required. Inspite of all of its benefits and studies bending tests were carried out. He found that AA
that has showed better performance than fusion 6082-T6 aluminum alloy revealed lower yield
weldings, FSW has not been still widely and ultimate stress as well as lowest hardness
commercialized around world, owing to lack of value[5].Raja Kumar et al.(2011) used 5 different
industry standards and specifications, design values for each of tool rotational speed, welding
guidelines and design allowable, informed speed, axial force, shoulder diameter, pin
workforce and high cost of capital equipment diameter and tool hardness parameters of FSW to
and licensing.FSW produces welds by using a understand influence of FSW process and tool
rotating, nonconsumable welding tool to locally parameters on strength properties of AA7075-T6
soften a work piece, through heat produced by aluminum alloy joints. He found that optimum
friction and plastic work, thereby allowing the parameters for providing maximum strength
tool to‘‘stir’’the joint surfaces. The tool serves properties of 315 MPa yield strength, 373 MPa
three primary functions, that is, heating of the of tensile strength, 397 MPa of notch tensile
work piece, movement of material to produce the strength, 203 HV of hardness and 77% of joint
joint, and containment of the hot metal beneath efficiency were 1400 rpm (tool rotational speed),
the tool shoulder. As of its invention, FSW 60 mm/min (welding speed),8 kN (axial
process has been found very interesting and force),with the tool parameters of 15 mm
widely studied. Many studies have been carried (shoulder diameter), 5 mm (pin-
out to understand and analyze the effect of diameter),45HRC(tool-hardness)[6].
process parameters and tool geometries on Kulekci_MK et al.(2008) studied effects of tool
microstructural and mechanical properties and rotation and pin diameter on fatigue properties of
formability of joints. Taban and Kaluc et friction stir welded lap joints of AA5754
al.(2007) successfully welded 6.45 mm thick aluminum alloy. Test results showed that
5086-H32 aluminum alloy with TIG, MIG and increasing one value while fixing other resulted
FSW processes, and their results has worse fatigue strengths[7].Kulekci_et
demonstrated that the tensile properties of FSW al.(2008)found that optimization of tool rotation
joints were more satisfactory than fusion welded and pin diameter were required to have better
joints[1]. Adamowski and Szkodo et al. (2007) fatigue performance. Sarsılmaz et al.(2012)found
investigated effect of process parameters on the that best fatigue performance was provided with
properties and microstructural changes in application of treated cylindrical pin profile,1120
Friction Stir Welds in the aluminum alloy 6082- rpm tool rotational speed and 250
T6 with 22 different parameters and found that mm/min[8].Ericsson and Sandstrom et
FSW welds is directly proportional to the tool al.(2003)studied influence of welding speed on
rotation and welding speeds [2]. Cavaliere et the fatigue of friction stir welds, and comparison
al.(2008)studied effect of varying welding speeds with MIG and TIG welded joints. According to
on mechanical and microstructural properties of the results, welding speed in the tested range,
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Vol. 5, No.1, February 2015

representing low and high commercial welding joints and fulfill the deficiency of knowledge
speed, had no major influence on the mechanical about these alloys as dissimilar FSWed joints.
and fatigue properties of the FS welds while FS Also, we used different parameters from
welds showed better fatigue performance then previous studies to vary knowledge about both
MIG and TIG[9].Lombard H et al.(2008)used 11 similar and dissimilar alloy joints of FSWed
different values of combination of tool rotational 5083-H111 and 6082-T651especially in low
speed, feed and pitch values for optimizing FSW welding speed.
process parameters to minimize defects and (FSW) is a solid-state joining technique which
maximize fatigue life in 5083-H321 aluminum was invented at The Welding Institute (TWI),
alloy. Their study has demonstrated that UK, in 1991.The FSW has been found to be
rotational speed governs defect occurrence in this effective for joining hard-to-weld metals and for
5083-H321 aluminum alloy and that there was a joining plates with different thickness or
strong correlation between frictional power different materials. In the FSW process a non-
input, tensile strength and low cycle fatigue life. consumable rotating tool with a specially
Although there were many achievements in FSW designed pin and shoulder is inserted into the
of aluminum alloys and both 5083-H111 and abutting edges of work pieces to be joined and
6082-T651 aluminum alloys were studied widely traversed along the line of the joint, as shown in
as similar alloy FSWed joints, there were not Fig.1.As the tool travels, heat is created by the
enough studies about these aluminum alloys as contact friction between the shoulder and the
dissimilar alloy joints. In contradiction to their workpiece, and by the plastic deformation of the
wide usage in industry, especially in shipbuilding materials in the stir zone. The high strain and
industry, there was not enough knowledge about heat energies experienced by the base metal
these alloys as dissimilar welds. We aimed to during stirring causes dynamic recrystallization,
contribute to knowledge of friction stir welding which is the formation of new grains in the weld
of 5083-H111 and 6082-T651 as similar alloy zone.

2 Materials and experimental procedure

In this study, 5083 and 6082 aluminum alloys 1250 rpm and 1050rpm rotational speed (counter
were used as base metals. Chemical composition clockwise), 65 mm/min and 55mm/min welding
and mechanical properties obtained by tensile speed. Tensile test specimens were prepared
test are given in Table 1. Aluminum alloy plates according to TS EN ISO 4136:2012.In order to
were cut into coupons according to TS EN ISO determine microstructure properties of these
15614-2 for butt welding. Mild steel tool with joints, the specimens were cross-sectioned
chemical composition of %0.05-0.320 C, % perpendicular to the weld interface using a
0.60-0.90 Mn, % 98.81-99.26 Fe, % < 0.04 P, % fatigue test specimens were analyzed with
<0.05 S, hardness of HRC71 and the dimensions scanning electron microscopy (SEM).
was used as FSW tool. Welding parameters were
Table 1: Chemical composition and mechanical properties of base metals.
Aluminium alloys Chemical composition (in wt. %) :-
Element Si Fe Cu Mn Mg Zn Cr Pb Ti Ga V Al
5083 0.1 0.30 0.02 0.50 4.22 - 0.08 0.01 0.02 0.01 0.01 94.73
6082 1.0 0.34 0.06 0.57 0.87 0.01 0.01 0.01 0.03 0.01 – 97.04
Table 2: Mechanical properties of aluminium alloys:-
Element Rp0.2 (MPa) Rm (MPa) Elongation
5083 239 331 16.4

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Vol. 5, No.1, February 2015

6082 321 329 11.1

Figure. 1- Schematic drawing of FSW process.

Figure.2- Plates of an aluminium-5083 & 6082

Figure.3- Tools = 1, 2 Rectangular shape (20,22mm diameter) 3, 4 Circular shape (20, 22 mm Dia)

Friction Stir Welding was operated on and thickness of platess is 6mm.Tool are of four
CNC machine at R&D centre for bicycle & types having circular and rectangular with 20mm
sewing machine Focal point Ludhiana.Welding and 22mm shoulder diameter and tool tip (pin
tools were four types rectangular and circular diameter) length is 6mm.There are two rotation
with the diameter of 20mm and 22mm and tool speed 1050mm and 1250rpm (counter
tip (pin dia) is 6mm of mild steel. Plates of clockwise), and welding speed 55mm/min and
aluminium 5083 & 6082 cut into 16 pieces of 65mm/min. One sided welding is done by butt
each having length-160mm and bredth-80mm joint as shown fig-4

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Vol. 5, No.1, February 2015

Figure. 4- A schematic illustration of FSW butt-joint, the two sheets has been represented
transparent to show the pin.

3. Result and discussion

3.1 Tensile testing

Tensile testing (tension testing) is a fundamental tensile testing, dumbbells are cut in the
material science test in which a sample is dimensions as shown in fig-5.Tensile testing is
subjected to a controlled tension until failure. done on tensile testing machine at INDIANA
The results from the test are commonly used to TEST, CALIBRATION AND
select a material for an application, for quality CERTIFICATION SERVICES Mohali. For
control, and to predict how a material will react tensile testing, a dumbble shape specimen is
under other types of forces. Properties that are prepared which have following dimensions–(fig-
directly measured via a tensile testing are 10) Overall length(L)-160mm,distance between
ULTIMATE TENSILE STRENGTH, maximum shoulders-100mm, gauge length(G)-
ELONGATION and reduction in area. From 62mm,diameter or width(w)-18mm,reduced
these measurements the following properties can section(A)-80mm,grip section-30mm and width
also be measured-YOUNG’s MODULUS, of grip section- 30mm,Thickness of plate (t) -
POISSION’S RATIO, YIELD STRENGTH and 6mm.
STRAIN-HARDENING characteristics. In

Figure.5- Prepared sample of dumbble for tensile testing

The most common testing machine used in refers to the fact that the machine must be able to
tensile testing is the UNIVERSAL TESTING generate enough force to facture the specimen.
MACHINE. This type of machine has two The machine must be able to apply the force
crossheads; one is adjusted for the length of the quickly or slowly enough to properly mimic the
specimen and the other is driven to apply tension actually application. Finally machine must be
to the test specimen. There are two types: able to accurately and precisely measure the
HYDRAULIC POWERED and guage length and forces applied; for instance, a
ELECTROMAGNETICALLY POWERED large machine that is designed to mesure long
MACHINES. The machine must have the proper elongations may not work with a brittle material
capabilities for the test specimen being tested. that experiences short elongations prior to
There are four main parameters–force, capacity, fracturing. Alignment of the test specimen in the
speed, precision and accuracy. Force capacity testing machine is critical, because if the
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Vol. 5, No.1, February 2015

specimen is misaligned either at an angle or be minimized by using spherical seats or U-

offset to one side, the machine will exert a joints between the grips and the test machine.
bending force on the specimen. This is especially From Table-3, tensile strength of welded
bad for brittle materials, because it will area of each sample is less than the tensile
dramatically skew the results. This situation can strength of base metals aluminium 5083
(300MPa) and 6082 (295MPa).
Tensile testing (table-3)
Sample Rotation speed Welding speed Tool diameter Tensile strength Elongation (%)
no. (mm) (MPa)
1 1050 55 20-Round 50.338 2.333

2 1050 65 20 23.191 1.167

3 1250 55 20 46.671 2.500

4 1250 65 20 40.539 2.327

5 1050 55 22-Rectangular 48.016 2.016

6 1050 65 22 12.228 0.917

7 1250 55 22 24.872 1.333

8 1250 65 22 47.187 2.750

9 1050 55 20-Rectangular 38.534 1.750

10 1050 65 20 42.317 1.936

11 1250 55 20 13.256 1.700

12 1250 65 20 33.567 0.417

13 1050 55 22-Round 46.067 0.700

14 1050 65 22 47.338 1.583

15 1250 55 22 22.621 1.417

16 1250 65 22 86.268 1.167

100
Tensile Strength

20‐round
50 22‐rectangular
20‐rectangulr
22‐round
0
1050‐55 1050‐65 1250‐55 1250‐65
Rotational Speed

Figure. 6-Tensile strength-rotational speed/welding speed bar chart

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100
80

tensile strength
60
22mm Round
40
20
0
1050‐55 1050‐65 1250‐55 1250‐65
rotational speed/welding speed

Figure. 7- Tensile strength – rotational speed/welding speed of 22mm diameter round shape tool bar
chart

3.2 Micro-hardness test

Microhardness (indentation hardness) tests are Vickers test can be used for all metals. The unit
used in mechanical engineering to determine the of hardness–Vickers pyramid number (HV) Or
hardness of a material to deformation. Several Diamond pyramid hardness (DPH).The hardness
such tests exist, wherein the examined material number can be converted into unit of pascals, but
is intended until an impression is formed; these should not be confused with a pressure, which
tests can be performed on a microscopic scale. also has units of pascals.The hardness number is
VICKERS HARDNESS TEST –This test was determined by the load over the surface area of
developed in 1921 by Robert L.Smith and the indentation and nit the area normal to the
George E. Sandland at Vickers Ltd as an force, and is therefore not a pressure.
alternative to the Brinell method to measure the From the table, overall or average hardness
hardness of materials. The Vickers test is often no. of base metal is 85-95HV02 and overall or
easier to use than other hardness tests since the average hardness no. of welded area of 5083 and
required calculations are independent of the size 6082 aluminium is 95-105.
of the indenter, and indenter can be used for all From obtained data or table, we conclude that
materials irrespective of hardness, is to observe welded area is harder than base metal surface.
the questioned materials ability to resist plastic So, welding has more strength and more
deformations from a standard source. The weldability
Vickers Hardness test – (Table - 4)
Sample Rotation Welding Tool diameter Hardness no. [base Hardness no.
no. speed speed (mm) metal HV02] [welded metal
HV02]
1 1050 55 20-Round 86 100
2 1050 65 20 85 98
3 1250 55 20 92 104
4 1250 65 20 91 102
5 1050 55 22-Rectangular 87 96
6 1050 65 22 89 98
7 1250 55 22 88 95
8 1250 65 22 90 99
9 1050 55 20-Rectangular 93 97
10 1050 65 20 94 100
11 1250 55 20 85 95
12 1250 65 20 90 99
13 1050 55 22-Round 86 104
14 1050 65 22 94 102
15 1250 55 22 92 101
16 1250 65 22 90 105

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106

104

hardness
102
22‐Round
100

98
1050‐551050‐651250‐551250‐65
rotation speed

Figure 8- Hardness no.–rotational speed/welding speed of 22mm Diameter round shape tool
bar chart

3. Conclusion more at high rotational and speed welding and

In this study, 6mm thick 5083 and 6082 elongation is minimum and use of round shape
aluminum alloys that used widely in ship tools will be preferred.
building industry were welded successfully with •
low rotational and welding speed and following By Vickers hardness test, average hardness
conclusions were drawn: no. of base metal is between 85-90 and average
• In this study, 6 mm thick 5083 H111 hardness of welded area is between 95-100.But
and AW 6082 T6 aluminum alloys that used hardness no. of samples which are welded with
widely in ship building industry were welded tool of round shape (22mm),rotational speed
successfully with friction stir welding in butt 1250rpm and welding speed 65mm/min is more
joint with 1050rpm and 1250rpm rotational than lower rotational and welding speed or
speed and also welding speed 55mm/min and rectangular shape of tool. Surface finish of
65mm/min. In this one sided welding tool have welded area is also good with these parameters
four types round(20mm),round(22mm), and tool. So, we conclude from the bar chart and
rectangular(20mm) and rectangular line chart (hardness no./tool shape or tool
(22mm).After friction stir butt joint welding, diameter and hardness no./rotational speed or
tensile testing and Vickers hardness tests were welding speed) that high rotational speed and
performed. From the experimental data, best welding speed welding welded with round
tensile strength and hardness of welded area is of shape(more diameter) has more hardness other
samples which are welded with round shape tool than welding with lower rotational and welding
with 22mm diameter and rotational speed speed and tool with rectangular shape and also
1250rpm and 65mm/min welding speed. So, from the hardness of base metals.
these welding samples have better welding
quality than other samples and welding of base
ACKNOWLEDGMENT
metals.
• I would like to expressF my deep and sincere
Friction stir welding with butt-joint of gratitude to my supervisors, Mr.Lakshmi
6mm thick of aluminium-5083 and 6082 have Shankar Assistant Professors in Department of
good welding quality. After welding of two Mechanical Engineering, University College of
plates for observing tensile strength, tensile Engineering, Punjabi University Patiala (Punjab).
strength testing was done. By calculating the I offer special regards to Research &
data of tensile strength and elongation bar chart Development centre for Bicycle & sewing
and line chart are drawn. From these bar and line Machine, focal point Ludhiana especially to Mr.
charts we investigate that average tensile Paramjit Singh (production manager), Mr. Y.A.
strength of samples welded with the round tool Khan (workshop head), Mr. Kulwant Singh
shape of 22mm diameter, rotational speed (Lathe machine operator), Mr. Harbhajan Singh
1250rpm and welding speed 65mm/min have and Mr. Om Prakash (cylindrical grinding
more tensile strength than rectangular shape tool machine operators) and Jaswinder kamboj
welding, and low rotational and welding speed (tensile testing machine operator) for their
welding and also elongation of these samples is immense support in performing the practical
minimum. So, we can say that tensile strength is work
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Vol. 5, No.1, February 2015

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