VOLUME 61

ISSUE 2
of Achievements in Materials December
and Manufacturing Engineering 2013

Comparative investigation of friction

stir welding and fusion welding of
6061-T6 and 5083-O aluminum alloy
based on mechanical properties and
microstructure
S. Jannet a, P.K. Mathews b, R. Raja a
a Karunya University, Karunya Nagar,
State Highway 164, Coimbatore, Tamil Nadu 641114, India
b Palathurai, Tamil Nadu 641105, India

* Corresponding e-mail address: id.sabithajannet@gmail.coml

Received 09.10.2013; published in revised form 01.12.2013

Materials

Abstract
Purpose: In this paper, the mechanical properties of welded joints of 6061 T6 and 5083 O aluminium
alloy obtained using friction stir welding (FSW) with four rotation speed (450, 560, 710 and 900 rpm) and
conventional fusion welding are studied.
Design/methodology/approach: FSW welds were carried out on a milling machine. The performance of FSW
and Fusion welded joints were identified using tensile, hardness and microstructure.
Findings: Better tensile strength was obtained with FSW welded joints. The width of the heat affected zone
of FSW was narrower than Fusion welded joints welded joints
Research limitations/implications: Properties FSW and Fusion Welded processes were also compared with
each other to understand the advantages and disadvantages of the processes for welding applications of the Al
alloy.
Originality/value: The results show that FSW improves the mechanical properties of welded joints.
Keywords: TIG; MIG; FSW

Reference to this paper should be given in the following way:

S. Jannet P.K. Mathews, R.Raja, Comparative investigation of friction stir welding and fusion welding of 6061-T6
and 5083-O aluminum alloy based on mechanical properties and microstructure, Journal of Achievements in
Materials and Manufacturing Engineering 61/2 (2013) 181-186.

1. Introduction
1. Introduction (FSW) on both microstructure and mechanical properties of an
Al-Mg-Si alloy. In TIG welding, an electric arc is formed between
consumable tungsten electrode and the workpiece. The arc
The present paper compares the influence of a fusion welding provides the thermal energy to melt the work pieces as well as the
techniques (TIG and MIG) and a solid-state welding technique filler if necessary. For Al alloys, due to their elevated thermal

© Copyright by International OCSCO World Press. All rights reserved. 2013 Research paper 181
 Journal of Achievements in Materials and Manufacturing Engineering Volume 61 Issue 2 December 2013

conductivity, the weld penetration remains very shallow: less than Table 2.
3mm in one pass. The elevated temperatures attained in fusion Chemical composition of filler metals (Wt%)
welding processes induce an important microstructural evolution
especially concerning hardening precipitates. Friction stir welding Filler Metal Si Mg Cu Fe Mn Zn Ti Cr Al
(FSW) is a solid-state joining technology patented by The Welding
Institute (TWI) in 1991. This process involves the advance of a AA 4043 5.0 0.05 0.30 0.80 0.05 0.10 0.2 - Bal.
rotating hard steel pin extended by a cylindrical shoulder between
two contacting metal plates. Frictional heating is produced from the
rubbing of the rotating shoulder with the two workpieces, while the
2.3. Experimental procedure
rotating pin deforms the heated material. Compared to fusion 2.3. Experimental procedure
welding processes, there is little or no porosity or other defects
related to fusion.In fact, the industrial interest of this study is to The plates of AA6061-T6 and AA5083-O aluminum alloy
evaluate the possible benefits of FSW compared to TIG,MIG were machined to the required dimensions (150mm×75×6mm).
considering the lower heat input of the solid-state joining process Butt joint configuration was prepared to fabricate GTA and GMA
and the high stability of hardening particles. welded joints. Single pass welding was used to fabricate the
joints. AA4043 (Al-5%Si) grade filler rod and wire were used for
GTA and GMA welding processes, respectively. High purity
2. Experimental
2. Experimentalworkwork (99.99%) argon gas was the shielding gas. Butt joint configuration
as shown in Fig. 1 was prepared to fabricate FSW joints. A non-
consumable, rotating tool made of high speed steel was used to
2.1. Base metal fabricate FSW joints. FSW is affected by process parameters such
2.1. Base metal
as rotational speed, welding speed and axial force. Compared to
Table 1. fusion welding processes, there is no porosity or other defects
Chemical composition of base metal related to fusion. However, the hardening precipitates responsible
for the good mechanical properties of heat treatable aluminum
Element Cr Cu Fe Mg Mn Si Ti Zn Al alloy are shown to be affected by this process, partly because of
AA 5083-O 0.05 0.100.40 4.90 0.40 0.40 0.15 0.25 Bal their low stability. The process parameters must be optimized to
get defect free joints. The optimum friction stir welding process
AA6061-T6 0.04 0.150.35 0.8 0.15 0.4 0.15 0.25 Bal. parameter for joining AA6061-T6 and 5083-O aluminum alloy
are 600 rpm, 18 mm/min and 6.5 kN. Trial experiments and
2.2. Filler materials microstructural analysis were carried out for each mentioned
2.2. Filler materials process to find out the optimum process parameters. The welding
conditions and optimized process parameters presented in Table 3
The 4xxx series alloys have Si added to reduce the melting were used to fabricate the joints.
point and to increase the fluidity in molten state.

Table3.
Welding conditions and process parameters
PROCESS GMAW GTAW FSW

Welding machine Lincoln USA Lincoln USA RV Machine Tools, India

Tungsten electrode diameter(mm) 1.6 3 _
Filler rod/wire diameter(mm) 1.6 3 _
Voltage (volts) 22.07 17.35 _
Current (amps) 186 170 _
Welding speed (mm/min) 188 64 10
Shielding gas Argon Argon _
Gas flow rate (lit./min) 9 9 _
Tool rotational speed (rpm) _ _ 600
Axial force (kN) _ _ 6.5
Tool pin profile _ _ Cylindrical threaded
Tool shoulder diameter (mm) _ _ 18
Pin diameter (min) _ _ 6
Pin length (mm) _ _ 5.8

182 Research paper S. Jannet, P.K.Mathews, R.Raja

 Materials

2.4. Weld
2.4. Weldaged treatment
aged treatment 3.2. Micro
3.2. Microhardness surveysurvey
hardness

In order to improve the mechanical properties and reducing Such hardness test has been made with a load as light as 1
the residual stress in the fabricated welded joins, post weld heat gram, although the majority of micro-hardness tests are made with
treatment was performed. The post-weld aging treatment was loads of 100 gram to 500 gram.. The degree of accuracy that can
carried out at 170°C for a soaking time of 7 h. be attained by the surface smoothness of the specimen tested. If
test load decreases, surface finish requirements become more
stringent. When the load is 100 grams or less a metallographic,
3. Properties
3. Propertiesevaluation
evaluation finish is recommended. But for this investigation applied load is
500 gram. The load is applied smoothly without impact and held
in place for 15 sec. The indenter is made of diamond and is in
form of a square base pyramid having an angle of 1360 between
3.1. Tensile properties
3.1. Tensile Properties faces. Micro-hardness is measured from the weld center to base
metal on both sides. Microstructure examinations have been
The tensile tests are carried out in the 100 kN capacity carried out using optical microscope to quantify various micro
electromechanical Universal Testing Machine at a displacement constituents present in the weld metals. Final polishing is done
rate of 0.5 mm/min. The weld metal specimens are tested in the using the diamond compound (1—m particle size) in the disc-
100 kN electromechanical testing machine in the same polishing machine. Samples are etched with keller’s reagent.
displacement rate. Load versus displacement was recorded in X-Y Microstructure analysis has been carried using VERSAMET-3
axis. The 0.2 percent offset yield strength was calculated from the light optical microscope with clemax-vision image analyzing
load stress diagram. The percentage elongation of the joint and system and the optical micrographs of weld zone are recorded.
the weld metal specimen are also estimated. Figs. 1 and 2 shows Fig 11 shows the microscope with clemax image vision system.
the before testing and after testing specimens respectively.

4. Results and discussions

4. Results and discussions

4.1. Tensile properties

4.1. Tensile properties

The tensile properties such as Ultimate Tensile Strength

(UTS), yield strength (YS) and (%) elongation, Notch Strength
Ratio (NSR) and Joint Efficiency are presented in the Tables 3
and 4.
The Tables 5, 6 shows the comparision details about BM, CC-
TIG, CC-MIG, PC-TIG, PC-MIG, FSW (Tensile Test) (Figs. 3-8).

Table 3.
As Weld For Smooth Specimen
Tensile
Peak load Yield strength
Joints strength
(kN) (MPa)
Fig. 1. Testing specimens (MPa)
CC-TIG 6.90 116 -
CC-MIG 11.50 192 158
PC-TIG 10.00 166 164
PC-MIG 11.07 189 176
FSW 12.05 200 184
BM 22.56 280 234

Table 4.
Post Weld Aging for smooth specimen
Peak load Tensile strength
Joints Yield strength (MPa)
(kN) (MPa)
CC-TIG 7.7 135 112
CC-MIG 15 215 186
PC-TIG 11.56 160 131
PC-MIG 16.8 201 180
Fig. 2. After testing specimens FSW 18.4 225 195

Comparative investigation of friction stir welding and fusion welding of 6061-T6 and 5083-O aluminum alloy based on… 183
 Journal of Achievements in Materials and Manufacturing Engineering Volume 61 Issue 2 December 2013

Table 5.
As Weld for notch specimen
Peak load Tensile strength
Joints
(kN) (MPa)
CC-TIG 4.4 82.5
CC-MIG 10.00 176
PC-TIG 9.02 137
PC-MIG 8.84 163
FSW 13.64 207

Table 6.
Post Weld for notch specimen
Peak load Tensile strength
Joints Fig. 6. Yield strength for smooth tensile specimen PWA
(kN) (MPa)
CC-TIG 10.47 159
CC-MIG 12.72 193
PC-TIG 10.15 153
PC-MIG 7.866 180
FSW 14.35 218

Fig. 7. Notch tensile strength for as welded

Fig. 3. UTS for as welded

Fig. 8. Notch tensile strength for PWA

4.2. Hardness
4.2. Hardness Properties
properties
Using vickers micro hardness, the hardness variation across
the weld metal, to base metal region are surveyed and the average
Fig. 4. UTS for PWA value are shown in Figs. 9, 10.

Fig. 5. Yield strength for smooth tensile specimen as welded Fig. 9. Hardness variation for as welded

184 Research paper S. Jannet, P.K.Mathews, R.Raja

 Materials

in the Fig 11. In Friction Stir Weldmentss, there is consiidarable

softnening through out th he weld zone, compared to th he base
material. Thhe minimum harrdness is locatedd around 8 mm from
fr the
weld centerr towards 5083--O side. Hardneess is relatively high in
the weld reegions of all the joints compared to heat affecteed zone
(HAZ) andd base metal (BM). The hardneess value is low w in the
weld regionn of CCMIG wh hen compared to other welding process.
p
The post weld
w ment has enhanceed the hardness of weld
aging treatm
region of alll the joints.
Fig. 10. Hardness variiation for PWA

5. D
Discussion
5.  ns
Discussions

5.1.. Tensile prooperties

5.1. Tensile Properties

F
From the tensile tests results (Fiigs 3-10 ) it is un
nderstood that
the FSW joints aare exhibiting superior tensiile properties
perfoormance compaared to MIG and a TIG welded d joints. The
reasoons for the betteer tensile perforrmance of the FSW joints are
the superior mechaanical propertiees of the weld d region.Ideal
microostructure in thee weld region.FS SW process the welding zone
woulld affected by thhe tensile fractuure. Due to the heat input the
weldding zone and H HAZ is affectedd by the tensile properties. In
MIGG welding proceess the fracturee occurred in th he HAZ. The
tensile properties woould not affect the welding zon ne, due to the
high welding strengtth. TIG weldingg has shown very y poor tensile
propeerties due to less welding strength.Post weld aging
treatm
ment has shoown better im mprovement in the tensile
propeerties for smooth and notch specimens. Pu ulsed current
multiipass TIG weldding of 5083-O O and 6061-T6 alloy section
imprroved the tensille properties off the weld com mpared to the
weldds produced by cconstant current TIG welding.

h images of weld zone (a)CC -M

Fig. 11. Opptical micrograph MIG (b)
5.2 Microstruc
5.2.  cture
Microstructure
CC-TIG (C C) PC-MIG (d) PC-TIG (E)FSW
The optical micrrographs of the fusion zone/nug
T gget region of
all thhe joints are displayed in Fig. 11.
1 From the miicro graphs, it
can bbe observed thatt the grain structture was column nar for CCTIG 6. Concclusions
6. Conclusions
weldds and fineaxed for PCTIG weldds. The structure increasingly
coarsser and columnaar for CCMIG welds.This
w defo
ormation leads The meechanical and meetallurgical propperties of TIG, MIG
M and
to thee formation of vvery fine equiaxeed recrystalized grains with in Friction Strrir Welded jointts dissimilar AAA 5083-O and 6061-T6
6
the fr
friction stir proceessed zone.Varioous dislocations with network are evaluatted in detail andd compared and d following concclusions
structure observed in the recrystalized grains.A hiigh density of derived froom the investigaation.The tensilee properties of welded
dislocations with nettwork structure observed
o in manny grains.FSW joints AA 5083-O and 6061-T6 6 aluminnium alloy joiints are
proceess imparts a larrge degree of plastic deformatio on to the work influenced by welding pro ocess and post weld
w aging treattment.A
piecee by the mechannical stirring action of a rotating tool. Previous reasonable increase in tenssile properties haas been attained
d for the
reaseearchers have reported that Thhis deformation n leads to the post weld aged joints as compared to as a welded jointss. Even
formmation of very fine equiaxed reccrystalized grtain ns with in the though, thee PWHT procedu ure is time consuuming and costlier, it is
frictiion stir processsed zone.variouus dislocations with network advantageoous to apply for the welds due to t above improv vements
structure observed in the recrystalized grains.A hiigh density of in tensile properties.
p Grainn refinement with fine distribu ution of
dislocations with network struucture observed in many precipitatess shows better strength and du uctility in FSWW joints.
grainns.Hence, the tennsile properties of FSW joints is superior as FSW jointss show comparaatively excellentt mechanical pro operties
comppared to MIG and TIG weelded joints du ue to thermo when comppared to TIG and MIG jointts. Micro Hard dness is
mechhanical processinng taking placee during friction n stir welding. relativley loower in the Heaat affected zone and higher in th he weld
Horizzontal profiles oof vickers hardnness in the weld d are indicated region. Thee micro hardnesss values are high h in the weld reegion of

Comparative investigation of friction stir welding and fusion welding of 6061-T6 and 5083-O aluminum alloy based on… 185
 Journal of Achievements in Materials and Manufacturing Engineering Volume 61 Issue 2 December 2013

FSW joints compared to MIG and TIG welded joints. Moreover, alloy, The Arabian Journal For Science and Engineering
the joints fabricated by FSW process exhibited superior 35/1B (2010).
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conventional welding processes. A comparison between FSW and TIG welding
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corrosion resistance in AA 2024-T3 butt joints, Journal of
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