metals

Article
A Case Study for the Welding of Dissimilar EN AW
6082 and EN AW 5083 Aluminum Alloys by Friction
Stir Welding
Sefika Kasman 1, *, Fatih Kahraman 2 , Anıl Emiralioğlu 2,3 and Haydar Kahraman 3,4
1 Izmir Vocational School, Dokuz Eylul University, Izmir 35160, Turkey
2 Department of Mechanical Engineering, Faculty of Engineering, Dokuz Eylul University, Izmir 35140,
Turkey; fatih.kahraman@deu.edu.tr (F.K.); anilemiralioglu@gmail.com (A.E.)
3 Graduate School of Natural and Applied Sciences, Dokuz Eylul University, Izmir 35140, Turkey;
haydar.kahraman@deu.edu.tr
4 Department of MetallurgicalandMaterialsEngineering, Faculty of Engineering, Dokuz Eylul University,
Izmir 35140, Turkey
* Correspondence: sefika.kasman@deu.edu.tr; Tel.: +90-533-731-4673

Academic Editors: Halil Ibrahim Kurt, Adem Kurt and Necip Fazil Yilmaz
Received: 10 November 2016; Accepted: 23 December 2016; Published: 29 December 2016

Abstract: The aim of this study is to investigate the effect of keeping constant the tool rotational
speed to the welding speed ratio (υ ratio) on the mechanical properties of the dissimilar friction
stir welding of EN AW6082-T6 and EN AW5083-H111. Two different pins shaped as triangular and
pentagonal were associated with the constant υ ratio. From the tensile test results, it was found
that the υ ratio does not create an evident change in the weld joint strength. The small cavity- and
tunnel-type defects were observed at the nugget zone and located on the advancing side of the pin.
These defects caused a decrease in the strength and elongation of the weld joint. The most important
inference obtained from the experimental results is that if the υ ratio is kept constant, the weld joint
strength for each weld does not correspond to a constant value.

Keywords: dissimilar friction stir welding; pin shape; mechanical properties

1. Introduction
It is well known that aluminum alloys have inherent and versatility properties such as resistance
to corrosion, good formability, a good strength to weight ratio, low density and electrical and thermal
conductivity. These properties make it a high-demand material compared to the steel alloys in
industrial application, particularly in the automotive, shipbuilding, packaging, construction and
architecture fields, etc. With the growth of demand for aluminum alloys in a wide variety of
applications, the welding and manufacturing process of aluminum alloys requires special knowledge
and experiences. The welding of aluminum alloys by fusion welding techniques produces some defects
such as pores, loss of some elements, hot cracking, stress corrosion cracking, and mismatch between
the filler alloy and the workpiece material in dissimilar welding, causing the loss of strength of the
weld joint [1]. To overcome these problems, the solid-state welding techniques are the best alternatives
for the welding of aluminum alloys.
Aluminum-magnesium alloys are non-heat-treatable alloys which provide good mechanical
properties, corrosion resistance, and good workability and weldability. These excellent properties make
it an attractive material in a wide range of construction and structural applications in the automotive
and shipbuilding industries. Aluminum alloy EN AW5083 is one of the aluminum-magnesium alloys
and it has high mechanical strength and fusion weldability [2]. The aluminum-magnesium-silicon

Metals 2017, 7, 6; doi:10.3390/met7010006 www.mdpi.com/journal/metals

Metals 2017, 7, 6 2 of 9

alloys are heat-treatable alloys and have a medium strength with excellent corrosion resistance.
These alloys are being used in automotive parts, especially in body sheets to decrease their weight.
EN AW6082 alloy is one of the aluminum-magnesium-silicon alloys and it has very good weldability,
but its strength is lowered in the weld zone [3]. Many studies have focused on the friction stir welding
(FSW) process of aluminum alloys and it is well known that some of aluminum alloys cannot be
welded by the fusion welding process. Therefore, in order to achieve more information about the FSW
process, critical factors such as the tool design, rotational speed and welding speed have been subjected
to investigation. There are many studies related to the FSW of EN AW5083 and EN AW6082, but the
dissimilar FS welding of these alloys is limited. Also, in most of the studies, the tool pin shape is a
straight, cylindrical threaded profile. There are some studies in the literature on dissimilar FS welding
of EN AW6082 and EN AW5083. Peel et al. [4] performed studies to determine the effect of the tool
rotational and welding speed on the microstructure of welding zones and weld properties of dissimilar
FSW EN AW5083–EN AW6082 joints. Donatus et al. [5] focused on identifying corrosion-susceptible
regions of dissimilar friction stir welds of EN AW5083-O and EN AW6082-T6. Donatus et al. [6]
performed dissimilar FSW studies on EN AW5083-O and EN AW6082-T6 to investigate the material
flow in the friction stir welds. Steuwer et al. [7] investigated the effect of the welding parameters on
the residual stress profiles on the same welds. Apart from these studies, Leitão et al. [8] conducted
two-stage experimental studies in order to determine the effect of FSW parameters on each material and
the weldability of dissimilar alloys at high temperature. Sun et al. [9] studied the dissimilar friction stir
welding of ultrafine-grained 1050 and 6061-T6 aluminum alloys to understand joint characterization.
Aval et al. [10] investigated the thermo-mechanical behavior and microstructural events of dissimilar
FSW of AA6061-T6 and AA5086-O.
The present study is focused on the effect of tool geometry and the ratio of the tool rotational
speed to the welding speed (υ ratio) on the mechanical and macrostructural properties of dissimilar
FSW of EN AW6082-T6 and EN AW5083-H111 alloys.

2. Friction Stir Welding

Friction stir welding is the alternative welding technique for some aluminum alloys that cannot
be welded by the fusion welding techniques. The major difference is that FSW occurs below the
melting point and it is located in the welding group occurring in the solid-state phase. The principles
of the FSW process are that a tool consisting of a shoulder and a pin plunges into the butted surface
of the plates and then the rotational and translational movement perform the welding process.
The necessary heat for welding is provided by the tool shoulder and pin, the speed of the tool
rotation and the movement. The friction between the tool pin and the workpiece generates the heat
and, therefore, the pin shape has a particular effect and an increase in the tool rotational speed increases
the heat. Also, the heat decreases with the increase in the tool movement speed or welding speed.
In this context, a mathematical approximation is developed as in Equation (1) [11,12].

Q = (αq)/W = 4/3 π2 (αµP.TRS.R3 )/WS = β.TRS/WS (1)

where Q is the heat input per unit length, α is the heat input efficiency, WS is the welding speed,
and TRS is the tool rotational speed. For a welding condition, α, µ, P, R and β are the constant values.
It is understood from Equation (1) that the tool rotational speed and the welding speed are the main
factors for determining the per unit heat input. By the effect of the generated heat, the material around
the pin flows from the front to the back of the tool and a deformation occurs from the tool movement.
Then, the weld joint is completed by repeating this cycle.

3. Materials and Methods

Aluminum alloys EN AW5083-H111 and EN AW6082-T6 plates with a thickness of 5 mm,
width of 150 mm and a length of 200 mm were used as the weld plates. The chemical composition
Metals 2017, 7, 6 3 of 9

Table 1. The chemical composition of aluminum alloys used in the present study (wt. %).

Alloy/Elements Cu Si Mg Mn Zn Ti Cr Fe Al
Metals 2017, 7,EN
6AW6082-T6 0.23 0.98 1.02 0.6 0.21 0.01 0.03 0.6 Bal. 3 of 9
EN AW5083-H111 0.056 0.093 4.19 0.53 0.09 0.007 0.083 0.243 Bal.

and the mechanical properties

Table of the plate materials
2. Mechanical were
properties of given alloys.
aluminum at Tables 1 and 2, respectively.
Before welding experiments, the butted surfaces of plates were cleaned from dust and any residue.
Alloy Ultimate Tensile Strength (MPa) Elongation (%)
1. The
Table EN chemical
AW6082-T6 composition of aluminum
293.21alloys used in the present8.12
study (wt. %).
EN AW5083-H111 325 17.6
Alloy/Elements Cu Si Mg Mn Zn Ti Cr Fe Al
The dissimilar FSW were
EN AW6082-T6 0.23 performed
0.98 with
1.02 a universal
0.6 milling
0.21 machine
0.01 (Russia).
0.03 For
0.6 the welding
Bal.
EN AW5083-H111 0.056 0.093 4.19 0.53 0.09 0.007 0.083 0.243 Bal.
experiments, a backing plate was used to place and clamp the plates. A schematic FSW experiment
and components was shown in Figure 1. The welding direction was set as the parallel to the rolling
direction of plates and theTable 2. Mechanical
tool was tilted at properties
the 2° to theof aluminum alloys.
normal direction of the plates. A sample
figure for FSW experiments was given in Figure 1. The welding tool was made of DIN EN 1.7131 steel
Alloy Ultimate Tensile Strength (MPa) Elongation (%)
and geometrically shaped as a triangular and pentagonal shown in Figure 2. The tool properties were
EN AW6082-T6
listed in Table 3. With the aim of analyzing the293.21 effect of the constant ratio of the tool 8.12 rotational speed
EN AW5083-H111 325 −1 17.6
to the welding speed “υ” (TRS (rpm)/WS (mm·min )), an experimental layout was conducted given
at Table 4. As shown in Table 4, the υ ratio was kept fixed at 10.
The
The dissimilar FSW were
macrostructural performed
analyses with a universal
were performed on the milling machineperpendicular
cross sectioned (Russia). For the welding
to the weld
experiments,
direction. Each a backing
sample wasplatesubjected
was usedtotothe place and clamp
standard the plates.
grinding A schematic
and etching process. FSWTheexperiment
etching is
and components
performed by thewasmodified
shown inKeller
Figure solution.
1. The welding direction
Following the was set aspreparations,
surface the parallel tothe the rolling
optical
direction of plates andwere
the tool ◦
was tilted at the 2 to the normal direction of the plates. A sample
macroscopic analyses done.
figureAfor FSW
joint experiments
fabricated by the was
FSWgiven in Figure
process 1. The welding
was characterized toolthe
with was made oftensile
ultimate DIN EN 1.7131(UTS,
strength steel
and geometrically shaped as a triangular and pentagonal shown in Figure
MPa) and percentage of elongation (ε, %). The tensile tests were carried out on 500 kN hydraulic 2. The tool properties were
Metals 2017, 7, 6 4 of 9
listed
testinginmachine
Table 3. (Shimadzu,
With the aim of analyzing
Kyoto, Japan) withthe effect of the constant
a cross-head speed ofratio
2 mm·of min
the tool rotational
−1. The samplesspeed
were
to the welding speedto“υ” ·min − 1
prepared according the(TRS
ASTM(rpm)/WS
E8-M. At (mmleast two)), an experimental
samples were tested
Table 4. FSW experimental layout with responses (UTS, ε, %).
layout
and was conducted
the average of given
those
at Table 4. As shown in Table 4, the υ ratio
tests was used in the final decision and analyses. was kept fixed at 10.
Process Parameters Welding Performance
Exp. No. υ Efficiency
PS TRS WS UTS (MPa) ε (%) Defect
TRS/WS 6082 5083
1 T 400 40 164.36 0.49 56.06 50.57 Defective
2 T 500 50 188.68 4.6 64.35 58.06 Defective
3 T 630 63 198 4.7 67.53 60.92 Defective
4 T 800 80 198.48 4.26 67.69 61.07 Sound weld
10
5 P 400 40 180.59 4.14 61.59 55.57 Defective
6 P 500 50 192.27 4.312 65.57 59.16 Defective
7 P 630 63 181.96 0.39 62.06 55.99 Defective
8 P 800 Figure 1. A sample
80 Figure 1. A sample187.85 for FSW experiment.
4.24 64.07 57.80 Defective
for FSW experiment.

Table 3. FSW process parameters and their levels.

Parameters (Unit) Symbol Levels

Tool Rotational Speed (rpm) TRS 400 500 630 800
Welding Speed (mm·min−1) WS 40 50 63 80
Tool Rotational Speed-to-Welding Speed υ 10
Pin shape PS T P
Fixed parameters
Tool shoulder diameter (mm) D 20
Tool tilt angle (°) α 2
Dwell time (s) t 20

Figure 2. The
The tool
tool pin
pin profiles used in the FSW experiment.

4. Results and Discussionanalyses were performed on the cross sectioned perpendicular to the weld
The macrostructural
direction. Each sample
The present study was subjected
focused on thetoeffect
the standard
of fixinggrinding
the ratioand etching
of the process. The
tool rotational etching
speed is
to the
welding speed “υ” on the microstructure and mechanical properties of dissimilar FS welding of EN
AW6082 to EN AW5083. In total, eight FSW experiments were performed and the results were
evaluated as below.

4.1. Macrostructure and Microstructure Investigations

Metals 2017, 7, 6 4 of 9

performed by the modified Keller solution. Following the surface preparations, the optical macroscopic
analyses were done.
A joint fabricated by the FSW process was characterized with the ultimate tensile strength
(UTS, MPa) and percentage of elongation (ε, %). The tensile tests were carried out on 500 kN hydraulic
testing machine (Shimadzu, Kyoto, Japan) with a cross-head speed of 2 mm·min−1 . The samples were
prepared according to the ASTM E8-M. At least two samples were tested and the average of those tests
was used in the final decision and analyses.

Table 3. FSW process parameters and their levels.

Parameters (Unit) Symbol Levels

Tool Rotational Speed (rpm) TRS 400 500 630 800
Welding Speed (mm·min−1 ) WS 40 50 63 80
Tool Rotational Speed-to-Welding Speed υ 10
Pin shape PS T P
Fixed parameters
Tool shoulder diameter (mm) D 20
Tool tilt angle (◦ ) α 2
Dwell time (s) t 20

Table 4. FSW experimental layout with responses (UTS, ε, %).

Process Parameters Welding Performance

Exp. No. υ Efficiency
PS TRS WS UTS (MPa) ε (%) Defect
TRS/WS 6082 5083
1 T 400 40 164.36 0.49 56.06 50.57 Defective
2 T 500 50 188.68 4.6 64.35 58.06 Defective
3 T 630 63 198 4.7 67.53 60.92 Defective
4 T 800 80 198.48 4.26 67.69 61.07 Sound weld
10
5 P 400 40 180.59 4.14 61.59 55.57 Defective
6 P 500 50 192.27 4.312 65.57 59.16 Defective
7 P 630 63 181.96 0.39 62.06 55.99 Defective
8 P 800 80 187.85 4.24 64.07 57.80 Defective

4. Results and Discussion

The present study focused on the effect of fixing the ratio of the tool rotational speed to the
welding speed “υ” on the microstructure and mechanical properties of dissimilar FS welding of
EN AW6082 to EN AW5083. In total, eight FSW experiments were performed and the results were
evaluated as below.

4.1. Macrostructure and Microstructure Investigations

A weld joint is characterized by three distinct zones and a sample is shown in the Figure 3.
The zones are affected by the tool rotational speed, welding speed and tool pin shape. The investigation
of the macrostructure for each weld joint in the context of the present study was performed on the
cross-section of the weld joints shown in Figure 3. As shown in Figure 3, the shape of nugget zone
(NZ) and thermomechanically affected zone (TMAZ) is highly affected from the FSW parameters and
pin shape. The pin shape shows the predominant effect on the NZ shape compared to the υ ratio.
The onion ring–type structure was detected all in the NZ. The visibility of onion rings in the NZ
produced by a pentagonal-shaped pin is more distinctive and the wideness of NZ is higher compared
to the triangular-shaped pin. The reason could be the dimension of the circumference of the pin.
The flow of deformed and elongated grains in the TMAZ is affected from the tool pin shape and
Metals 2017, 7, 6 5 of 9

Metals 2017, 7, 6 5 of 9
ring is sectioned as vertical, it is seen that a part of the onion ring closer to the joint root is composed
from EN AW6082. The reason is due to the rotation of the tool and the placement of EN AW6082. An
onion
generatedringheat.
is composed
The width of of
a dark
the TMAZand a isbright
bigger ring.
at theThese rings grow
condition of Exp.outward from
3,4,7,8. It the centertoand
is attributed the
are placed
higher heatininput.
the nugget
As seen zone as they are
in Equation (1),ordered consecutively.
an increase The composition
in TRS increases the heat inputof thedueonion rings
to higher
depends
frictional on the[12]
heat toolandrotational speed.
this causes The welding
an increase in widthspeed determines
of the TMAZ. Exp. the rotation times
3,4,7,8 were of the toolwith
performed per
minute.
a higherThe TRS.material forged by the tool and is moved from one side to the other side which is repeated
manyFigure
times 4byshows
the effect of tool
a sample rotational speed.
microstructure takenThis effect
from thecauses the forming
weld joint of Exp. of onion
6 and rings.
8. The regions
Two defective
and borders welds shown
of the welded metals in canFigure 5 were
be clearly taken from
detected due tothe joint fabricated
different by the triangular-
etching behavior. The flow
shaped pin at the
of the material TRSs
in the of 400zone
nugget andshows
500 rpm and WSsaccording
differences of 40 and to50 the
mm· min−1of
value . Tunnel-
TRS andand WS.cavity-type
The shape
defects wererings
of the onion clearly detected
is similar forfrom the weld
the entire weld joint and
joint and similar
almostdefects
has anwere alsoform.
elliptical observedWhen at the
the onion
other
joints.
ring is The defects
sectioned aswere located
vertical, at thethat
it is seen side of the
a part of pin tip and
the onion ENcloser
ring AW6082.
to theThere
joint is more
root than one
is composed
small
from ENdefect and these
AW6082. Thecaused
reasona is decrease in the
due to the mechanical
rotation of theproperties
tool and the of the weld joints.
placement of EN The reason
AW6082.
of formed
An onion ring defects is the amount
is composed of a dark of and
heata input; in some
bright ring. Thesecases,
ringsa grow
higher or insufficient
outward from the heatcenterinput
and
produced
are placeddefects, and especially
in the nugget zone as theyinsufficient heat consecutively.
are ordered input resulted The in inadequate
composition material flow which
of the onion rings
led to tunnel-
depends on theortoolcavity-like
rotationaldefects.
speed. In Thethe presentspeed
welding study, the small the
determines clustered
rotationdefects
times of at the
thetool
rootper
of
weld
minute. joint
Thewere clearly
material observed
forged by the toolandandappeared
is moved atfrom
bothonetheside
advancing andside
to the other retracting
which isside. The
repeated
possible
many times reason
by thefor effect
these of
defects is insufficient
tool rotational speed. heat
Thisinput.
effect causes the forming of onion rings.

Figure 3. Cross-section of each weld joint.

Two defective welds shown in Figure 5 were taken from the joint fabricated by the
triangular-shaped pin at the TRSs of 400 and 500 rpm and WSs of 40 and 50 mm·min−1 .
Tunnel- and cavity-type defects were clearly detected from the weld joint and similar defects were
also observed at the other joints. The defects were located at the side of the pin tip and EN AW6082.
There is more than one small defect and these caused a decrease in the mechanical properties of the
Metals 2017, 7, 6 6 of 9

weld joints. The reason of formed defects is the amount of heat input; in some cases, a higher or
insufficient heat input produced defects, and especially insufficient heat input resulted in inadequate
material flow which led to tunnel- or cavity-like defects. In the present study, the small clustered
defects at the root of weld joint were clearly observed and appeared at both the advancing and
retracting side.
Metals 2017, 7, 6 The possible reason for these defects is insufficient heat input. 6 of 9
Metals 2017, 7, 6 6 of 9

Figure 4. Nugget zone structures consisting of

of onion rings.
rings.
Figure 4. Nugget
Figure 4. Nugget zone
zone structures
structures consisting
consisting of onion
onion rings.

Figure 5. Samples for defective weld joints (Exp. 1 and Exp. 2).
Figure5.
Figure 5. Samples
Samples for
for defective
defective weld
weld joints
joints (Exp.
(Exp. 11 and
and Exp.
Exp. 2).
2).

4.2. Mechanical Properties

4.2. Mechanical
4.2. Mechanical Properties
Properties
In order to determine the mechanical properties of each weld joint, the tensile tests were
Inorder
In ordertoto determine
determine the mechanical properties of eachofweld
eachjoint,
weld joint, the tensile tests were
conducted and the results the
weremechanical
associatedproperties
with the process parameters. theThe
tensile tests
ultimate were
tensile conducted
strength
conducted
and andwere
the results werewithassociated with the process parameters. The ultimate tensile strength
(UTS) and percentage of elongation (ε, %) were considered as the process responses. The tensile and
the results associated the process parameters. The ultimate tensile strength (UTS) test
(UTS)
percentageand percentage
ofgiven
elongation of elongation
(ε, %) (ε,
wereFigures %)
consideredwere considered
as7.the process as the process responses. The tensile test
results were in Table 4 and 6 and Also, the responses. The tensile
fracture location of each testweld
results were
joint is
results
given were given in Table 4 and Figures 6 and 7. Also, the fracture location of each weld joint is
shownininTableFigure4 and
8. AsFigures
shown 6 and 7. Also,
in Figure the fracture
8, except locationofofExp.
the welding each1weld joint 7,
and Exp. is the
shown in Figure
fracture of the 8.
shown
As shown in Figure 8. As shown in Figure 8, except the welding of Exp. 1 and Exp. 7, the fracture of the
joints was in Figureat8,the
located except
heat the welding
affected zoneof(HAZ)
Exp. 1and andthe
Exp. 7, the
side fracture
of EN AW6082. of the Thejoints was located
fracture for the
joints
at the was located
heat affected atzone
the (HAZ)
heat affected
and zone
the side (HAZ)
of EN and the side
AW6082. The offracture
EN AW6082. for the The fracture
welding of for
Exp. the
welding of Exp. 1 and Exp. 7 was located at the nugget zone. As mentioned before, except Exp. 4, all1
welding
and Exp. of Exp. located
7 was 1 and Exp.the 7 was located at the nugget zone. As mentioned before,
4, allexcept Exp. 4, all
the weld joints containedatmany nugget zone.
small defects As mentioned
such as cavitiesbefore, except
and some of Exp.
the joints the
as inweld
Exp. 2joints
had
the weld
contained joints
many contained
small many
defects small
such as defects
cavities such
and as cavities
some of theand some
joints as of
in the
Exp. joints
2 had as ain Exp.
tunnel-type2 had
a tunnel-type defect. From Figure 6, the effects of the defects on the UTS can be clearly seen and all
a tunnel-typeFigure
defect. defect.6,From Figure of6,thethe effectson ofthe
theUTS
defects on the UTSseencan and
be clearly the seen
UTS and all
the UTSFrom values are lower the than
effectsthose of defects
the base materials. can
Thebe clearly
UTS value for the all triangular-shaped values
the UTS values
are are lower than those of the base materials.forThe UTS value for the pin triangular-shaped
pin lower than those
increased with of thethe base materials.
increase of the tool The UTS value speed
rotational the independent
triangular-shaped of the weldingincreased with
speed.
pin
the increased
increase of with
the toolthe increase
rotational of
speed the tool rotational
independent of speed
the independent
welding speed. of the
However, welding
this speed.
tendency
However, this tendency was not observed for the pentagonal-shaped pin. The UTS for Exp. 1 was the
However, this tendency was not observed for the pentagonal-shaped pin. The UTS for Exp. 1 was the
lowest (164.36 MPa) one of all in the weld joint and it corresponded to 56.06% efficiency for EN
lowest (164.36 MPa) one of all in the weld joint and it corresponded to 56.06% efficiency for EN
AW6082. The ε value in Figure 7 was verified by the UTS result. The value of ε was 0.49 and, also,
AW6082. The ε value in Figure 7 was verified by the UTS result. The value of ε was 0.49 and, also,
the fracture location of this joint was at the NZ and we observed that there was no significant
the fracture location of this joint was at the NZ and we observed that there was no significant
elongation compared with the other joints. A similar result was observed at the welding of 630 rpm
elongation compared with the other joints. A similar result was observed at the welding of 630 rpm
and 63 mm·min−1−1(Exp. 7) produced by the pentagonal-shaped pin. The fracture location was also at
and 63 mm·min (Exp. 7) produced by the pentagonal-shaped pin. The fracture location was also at
Metals 2017, 7, 6 7 of 9

was not observed for the pentagonal-shaped pin. The UTS for Exp. 1 was the lowest (164.36 MPa)
one of all in the weld joint and it corresponded to 56.06% efficiency for EN AW6082. The ε value in
Figure 7 was verified by the UTS result. The value of ε was 0.49 and, also, the fracture location of this
joint was at the NZ and we observed that there was no significant elongation compared with the other
joints. A similar result was observed at the welding of 630 rpm and 63 mm·min−1 (Exp. 7) produced
by the2017,
Metals pentagonal-shaped
7, 6 pin. The fracture location was also at the NZ. According to the UTS results, 7 of 9
Metals
the 2017, 7, 6with the highest strength was performed at the condition of 800 rpm and 80 mm·min−71 of
welding by9
the triangular-shaped
difference between thepin, twoand UTS anvalues
important issue
is small was observed
enough relating
to be ignored. to the
It can beUTS
takenvalues
as anfor both of
important
difference
Exp. 3 andforbetween
Exp. theresults
two UTS values is small enough to be ignored. It canthebe taken asvalues
an important
inference the4:strength
the andarethealmost the
elongation same. The
of the difference
welded between
samples; the results two UTS
are smaller is small
than the
inference
enough to for
be the strength
ignored. It and
can be the elongation
taken as an of the welded
important samples;
inference for thethe resultsand
strength are the
smaller than the
elongation of
base metals’ UTS and ε. The welding efficiency was determined by comparing the UTS values for all
base metals’
the welded UTS and
samples; ε. The
the base welding
results efficiency
are smaller was
than the determined
base metals’ by comparing
UTS4.and the UTS
The welding values for all
efficiency
weld joints with the metals. The results were listed in Table It isε. obvious that the lowest
the weld
was joints with
determined by the base metals.
comparing the UTS The results
values for were
all the listed
weld injoints
Table 4. Itthe
with is obvious
base that The
metals. the lowest
results
efficiency was obtained from the defective weld joints. The efficiency for joint strength ranged from
efficiency
were listed wasTable
obtained
4. Itfrom the defective theweld joints. The efficiency for joint strength ranged weld
from
55% to 68%.inAs is obvious
an association that the
between lowest
UTSs ofefficiency
weld joints was andobtained
UTSs offrom basethe defective
materials, a result
55% toThe
joints. 68%. As an association
efficiency between the UTSs of weld jointsAs and
an UTSs of base materials, a result
was reached: defectsfor
causejointthe
strength
decreaseranged
of thefrom
UTS55%andtoε 68%.
of FSW association
samples compared between the UTSs
to those of baseof
was
weld reached:
joints anddefects
UTSs cause
of the
base decrease
materials, of
a the
resultUTSwasand ε of
reached: FSW samples
defects cause compared
the to
decrease those
of of base
the UTS
materials.
materials.
and ε of FSW samples compared to those of base materials.

Figure 6.
6. The
The comparative
comparative UTS
UTS results
results for both
both tool pins.
pins.
Figure
Figure 6. The comparative UTS results for
for both tool
tool pins.

Figure 7. The
Figure 7. The comparative
comparative εε results
results for
for both
both tool
tool pins.
pins.
Figure 7. The comparative ε results for both tool pins.
Metals 2017, 7, 6 8 of 9
Metals 2017, 7, 6 8 of 9

Figure
Figure 8. The
The fracture
fracture location
location of weld samples after tensile tests.

5.
5. Conclusions
Conclusions
The present study
The present studyfocused
focusedononthe
the effect
effect of the
of the ratio
ratio of tool
of the the tool rotation
rotation speedspeed
to theto the welding
welding speed
speed (υon
(υ ratio) ratio) on the properties
the tensile tensile properties and macrostructural
and macrostructural alteration
alteration for dissimilar
for dissimilar friction
friction stir stir
welding
welding of EN AW6082 to EN AW5083 aluminum alloys. Two different pin shapes
of EN AW6082 to EN AW5083 aluminum alloys. Two different pin shapes were associated with a were associated
with a constant
constant υ ratio.υThe
ratio. The following
following conclusions
conclusions were drawn.
were drawn.
 The pin shape has a significant effect on the tensile properties and microstructure. The strengths
• The pin shape has a significant effect on the tensile properties and microstructure.
of the weld joint fabricated by the pentagonal-shaped pin was smaller than those of triangular-
The strengths of the weld joint fabricated by the pentagonal-shaped pin was smaller than those of
shaped pin for Exp. 7 and Exp. 8.
triangular-shaped pin for Exp. 7 and Exp. 8.
 The highest tensile strength was obtained from the weld joint fabricated with a triangular-
• The highest tensile strength was obtained from the weld joint fabricated with a triangular-shaped
shaped pin and the UTS and ε values were 198.48 MPa and 4.26%, respectively.
pin and the UTS and ε values were 198.48 MPa and 4.26%, respectively.
 The efficiency for joint strength is ranged from 55% to 68%. The variation trend changes
• The efficiency
depending onfor
bothjoint strength
defects is ranged
in the fromand
weld joint 55%the
to 68%. Theof
strength variation
the basetrend changes depending
material.
 on bothfor
Except defects in theweld
the fourth weldjoint,
joint the
andothers
the strength of the
contained basecavity
small material.
and tunnel defects.
• Except for the fourth weld joint, the others contained small
The fracture of each joint except in Exp. 1 and Exp. 7 was located at cavity and
thetunnel
side ofdefects.
EN AW6082.
• The nugget
The fracturezone
of each jointwas
profile except in Exp.
affected by 1the
and Exp.
pin 7 was
shape. Thelocated
nuggetatzone
the side of EN
of each AW6082.
weld contained
• The nugget zone profile was affected by the pin shape. The nugget zone of
onion rings. The shape of the onion rings was dependent on the value of the tool rotational each weld contained
speed
onion
and rings. The
welding shape of the onion rings was dependent on the value of the tool rotational speed
speed.
 and effect
The welding of aspeed.
constant υ ratio on the profile and structure of the nugget zone is dependent on
• The effect
both of a constant
the welding speed υ ratio
and toolonrotational
the profile and structure of the nugget zone is dependent on
speed.
 both
At the welding
a lower speed and
tool rotational tool rotational
speed and welding speed.
speed for each tool pin shape, lower UTS values
• were obtained.
At a lower toolThe UTS increased
rotational speed and as the tool rotational
welding speed forspeed and pin
each tool the welding speedUTS
shape, lower increased,
values
whileobtained.
were keeping the Theυ UTS
ratioincreased
constant for thetool
as the triangular-shaped
rotational speed pin.
and the welding speed increased,
while keeping the υ ratio constant for the triangular-shaped pin.
Acknowledgments: The present study is supported by a scientific project research (No. 2011.KB.FEN.045).

Author Contributions:
Acknowledgments: TheSefika
presentKasman
study isand Fatih Kahraman
supported designed
by a scientific the
project experiments;
research Anıl Emiralioglu and
(No. 2011.KB.FEN.045).
Haydar Kahraman performed the experiments with Sefika Kasman and Fatih Kahraman; all authors analyzed
Author Contributions: Sefika Kasman and Fatih Kahraman designed the experiments; Anıl Emiralioglu and
the data and contributed to written of paper.
Haydar Kahraman performed the experiments with Sefika Kasman and Fatih Kahraman; all authors analyzed the
data and contributed
Conflicts of Interest: to
Thewritten
authorsof declare
paper. no conflict of interest.
Conflicts of Interest: The authors declare no conflict of interest.
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