See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/283096092

Investigation on mechanical properties of welded aluminium joints of AA 8011

using friction stir welding

Article  in  International Journal of Applied Engineering Research · January 2015

CITATIONS READS

2 845

4 authors, including:

Selvaraj G Govindaraj Karthikeyan Thangavelu

Selvam College of Technology M.I.E.T Engineering College
3 PUBLICATIONS   4 CITATIONS    35 PUBLICATIONS   129 CITATIONS   

SEE PROFILE SEE PROFILE

All content following this page was uploaded by Karthikeyan Thangavelu on 24 January 2017.

The user has requested enhancement of the downloaded file.

 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 13 (2015)
© Research India Publications ::: http://www.ripublication.com

INVESTIGATION ON MECHANICAL PROPERTIES OF WELDED ALUMINIUM JOINTS OF AA

8011 USING FRICTION STIR WELDING

G.SELVARAJ3, Dr. T. KARTHIKEYAN2, R. MOHANADASS3, S.INDHUMATHI4

1
Associate Professor & Head, Department Of Mechanical Engineering, Selvam College of Technology,
Namakkal, India, Email: selvayuva@gmail.com
2
Professor & Principal, Department Of Mechanical Engineering, Arulmurugan College of Engineering, Karur,
India, Email: keian@rediffmail.com
3
PG Scholar, Department Of Mechanical Engineering, Selvam College of Technology, Namakkal, India
Email: mohanadass.r@gmail.com
4
Assistant Professor, Department of Electronics and Communication, Selvam College of Technology,
Namakkal, India, Email: indhuece028@gmail.com

ABSTRACT
The usage of aluminum alloys in automotive and aerospace applications is ever increasing due to their light
weight and cast-ability. Friction stir welding (FSW) is widely used for the welding of aluminum. This process uses a
non-consumable tool to generate frictional heat in the abutting surfaceswithout bulk melting. Welding input parameters
play a very significant role in determining the quality of a weld joint. The welding parameters such as tool shoulder
diameter, tool rotational speed, welding speed play a major role in deciding the joint strength. Therefore, welds made
by FSW are shown to have much improved mechanical properties than the corresponding fusion welds. In this Research
work similar joints of AA8011 alloy mechanical and metallurgical properties was investigated with process parameters
such as tool rotation speed, welding speed & Axial Force in detail.
Keywords: Aluminum Alloy AA8011, FSW, Butt Joints, Tensile Strength

1. INTRODUCTION

Aluminum alloys find wide applications in aerospace, automobile industries, railway vehicles, bridges, high
speed ships and military applications due to its light weight and higher strength to weight ratio [11] Friction stir welding
(FSW) is a material joining process. It is a highly important and recently developed joining technology that produces a
solid phase bond in which the material that is being welded does not melt and recast. Friction Stir Welding (FSW) has
greater potential for aluminum alloys since it can significantly reduce weld defects such as porosity, cracks and
distortions commonly encountered in fusion welded joints [11]. In Friction Stir Welding the process variables such as
rotation speed, travel speed, tool geometry has a vital role to develop quality joints [6]. FSW is considered to be the
most significant development in metal joining in a decade and is a “green” technology due to its energy efficiency,
environment friendliness, and versatility. Therefore,the FSW process can also be used to weld aluminum alloys in order
to obtain high quality joints.FSW creates the weld joint without bulk melting. In present study an attempt has been
made to check the effect of various friction stir welding parameters on mechanical and metallurgical properties of
AA8011 aluminum alloy.

2. MATERIAL AND TOOL DETAILS:

(i) Base Material (AA 8011):

The Similar material aluminum alloy AA8011 was used in this investigation. Chemical compositions of the
alloy material are given in the Table.1. Mechanical properties of aluminum alloy were given in Table.2. The Similar
aluminum alloy used in this investigation was welded using Friction stir welding technique.

CHEMICAL
Fe Si Mn Mg Zn Cu Ti Cr Al
COMPOSITION
AA 8011 0.74 0.52 0.46 0.28 0.084 0.13 0.016 0.028 Rem.

Table 1. Chemical composition of AA 8011 aluminum alloys

11095
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 13 (2015)
© Research India Publications ::: http://www.ripublication.com

Tensile Thermal Melting

MECHANICAL Density Hardness
Strength conductivity point
PROPERTIES Kg/m3 HRB
MPa W/m-k C
AA 8011 110 2689 237 660.2 60

Table 2. Mechanical properties of AA 8011 aluminum alloys

(ii) Tool Details:

There are many types of tool materials available for FSW. In this experiment circular shape high carbon high
chromium tool was used.
Dimensions and chemical composition of Tool will be given in Table.3.and Tool Geometry will given in
Figure.1.
Details Dimensions
Pin Length, L (mm) 5.7
Tool shoulder diameter, D (mm) 18
Pin diameter, d (mm) 6
D/d Ratio of tool 3.0
Tool pin geometry Circular
Pitch (mm) and included angle (deg) of
1 and 60
threaded pin
Chemical composition of the tool C-2.75, Si-0.60 max, Mn-0.60max
(wt %) Cr-13.5, Ni-.30 max, Grade- D3
(High carbon steel High Chromium Steel)

Table 3. Details of FSW Tool Dimensions

Figure 1. Tool Geometry

3.EXPERIMENTAL WORK

The rolled plates of 6mm thickness AA8011 aluminum alloys were cut into required sizes (50 mm width x 100
mm length) using power hacksaw. A square but joint configuration was prepared to carry out the FSW joints. The initial
joint configuration was obtained by securing the plates in position using mechanical clamps. The direction of welding
was normal to the rolling direction .Non consumable tool made up of High carbon High Chromium Steel was used for
joining process. The aluminum alloys were joined by varying rotational speed in four levels namely 900, 1200, 900,
1200 and traverse speed in three levels namely 40, 60, 40 and 60 mm/min with the axial force of 10 KN.

11096
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 13 (2015)
© Research India Publications ::: http://www.ripublication.com

The tool used for fabricating the joints is made by High carbon High Chromium Steel of diameter 20 mm with
shoulder diameter as 18mm and with a cylindrical pin of diameter 6mm. With the identified process parameters the
joints were fabricated. The fabrication process will be given in Figure 2. As shown in Figure. 3 the direction of welding
has been normal to the rolling direction. Single pass welding procedure has been followed to fabricate the joints.

Figure 2. Fabrication Method

Figure 3. Scheme of welding with respect to rolling direction

3. TESTING

(i) Tensile Test:

The welded joints have been sliced using a powerhacksaw and then machined to the required dimensionsas
shown in Fig. 4. Tensile specimens have beenfabricated as per the American Society for Testing ofMaterials standards
to evaluate thetensile strength of the joints. Tensile strength of the FSWjoints has been evaluated by conducting test on
universaltesting machine. The test specimen and fractured piece isshown in Fig.5.

Figure 4. Dimensions of tensile specimen

(ii) Hardness Test:

Rockwell Hardness testing machine was employed with 100kgf load for measuring the hardness of the weld
region. Five readings were taken in the weld region of the joint at close proximity distance and mean values are used for

11097
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 13 (2015)
© Research India Publications ::: http://www.ripublication.com

further analysis. That the reading has been noted by B SCALE HRB 1/16 BALL INDENTER.Photograph of Hardness
specimen will shown in Figure 5.

Figure.5 Photographic image of hardness tested welded specimens

(iii) Microstructure Analysis:

The microstructure of weld region of the defect free joints was analyzed using Optical Microscopy (OM). The
sample preparation adopted in this techniquehelped in obtaining OM images with better clarity. Samples of OM
analysis will given in figure 6.

Figure.6 Photographic image of SEM image specimens

4. RESULT & DISCUSSION:

(i) Tensile Test:

Tensile test was taken from Universal testing specimen; the results will given in following table 4.The
parameter range of tool rotational speed 900 RPM and welding speed of 40 mm/min can gives the high range of Tensile
Strength to other parameters.

PROCESS YIELD BREAKING YIELD STRESS BREAKING STRESS

S.NO
PARAMETER POINT (KN) POINT (KN) (N/MM2) (N/MM2)
1 1200 – 60 5 8.2 0.005 0.0082
2 900 – 60 5 6.8 0.005 0.0068
3 900 – 40 6 9.3 0.006 0.0093
4 1200 – 40 5 8.3 0.005 0.0083

Table 4. Details of Tensile test Results

(ii) Hardness Test:

The hardness of the welded specimen was measured using Rockwell Hardness testing machine for various
welded specimens with varying rotational speed and transfer speed were prepared and tested. Form the Rockwell
hardness test the welding speed of 60 mm/min and the tool rotational speed of 900 RPM is the given good range of

11098
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 13 (2015)
© Research India Publications ::: http://www.ripublication.com

hardness value of 82 HRB 1/16” BALL INDENTER IN B SCALE. The increase in rotational speed beyond this critical
limit resulted in decrease in hardness.

HARDNESS
RESULT
WELDING ROTATIONAL
S.NO MATERIAL (HRB 1/16
SPEED SPEED
BALL
INDENTER)
1 AA 8011 40 900 39
2 AA 8011 40 1200 52
3 AA 8011 60 900 82
4 AA 8011 60 1200 49

Table 5. Details of Hardness test Results

(iii) Microstructure Analysis:

From the micrographs, it can be inferred that the weld region of all the joints invariably contain uniformly
distributed. However, the size of the particles is different and it is found to be influenced by the tool rotation speed. The
presence of tool rotational speed 900 RPM and welding speed of 40 mm/min was very fine and uniformly distributed
particles in the weld region may also be one of the reasons for higher tensile strength of these respective joints.

WELDING ROTATIONAL
S.NO MATERIAL MICROGRAPHS
SPEED SPEED

1 AA 8011 40 900

2 AA 8011 40 1200

3 AA 8011 60 900

4 AA 8011 60 1200

Table 6. Details of Microstructure Analysis

5. CONCLUSION

From the above investigation it is observed that –

1. In this investigation an attempt was made to weld aluminum alloy of AA8011 using indigenously designed and
developed friction stir welding machine and the effort was very successful.
2. Tool rotation speed, traverse speed, axial force and tool design are the most significant process parameters in friction
stir welding.
3. The parameter range of tool rotational speed 900 RPM and welding speed of 40 mm/min can gives the high range of
Tensile Strength to other parameters.
4. The presence of tool rotational speed 900 RPM and welding speed of 40 mm/min was very fine and uniformly
distributed particles in the weld region may also be one of the reasons for higher tensile strength of these respective
joints.

11099
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 13 (2015)
© Research India Publications ::: http://www.ripublication.com

5. Form the Rockwell hardness test the welding speed of 60 mm/min and the tool rotational speed of 900 RPM is the
given good range of hardness value of 82 HRB 1/16” BALL INDENTER IN B SCALE.
6. Furthermore study can be carried out on the parameters like rpm of tool, tool feed rate, tool tilt angle and tool life.

6. REFERENCES

1. Balasubramanian V. (2008) „Relationship between base metal properties and friction stir welding process
parameters‟ , Materials Science and Engineering A, Vol.480, pp.397-403.
2. Cavaliere P., Campanile G., Panella F. and Squillace A. (2006) „Effect of welding parameters on mechanical
and microstructural properties of AA6056 joints produced by Friction Stir Welding‟ , Journal of Materials
Processing Technology, Vol.180, pp.263–270.
3. K. Elangovan, V. Balasubramanian and S. Babu, “Predicting tensile strength of friction stir welded 6061
aluminium alloy joints by mathematical model”, Materialanddesign, 30, 188-193, (2009).
4. Lakshminarayanan A.K., Balasubramanian V. and Elangovan K. (2007) „Effect of welding processes on
tensile properties of AA6061aluminium alloy joints ‟ , International Journal of Advanced Manufacturing
Technology, DOI 10.1007/s00170-007-1325-0.
5. P. Cavaliere , G. Campanile, F. Panella , A. Squillace, Effect of welding parameters on mechanical and
microstructuralproperties of AA6056 joints produced by Friction Stir Welding, Journal of Materials Processing
Technology 180 (2006) 263–270.
6. Ramkumar A, Sivapragash M, Saji Varghese, 2013, “Taguchi-Grey Based Optimization of Process Parameters
on AZ91D Mg Alloy by FSW, American Journal of Scientific Research, Issue 87, 156 – 163.
7. Santella M.L., Engstrom T., D. Storjohann and Pan T.Y. (2005) „Effects of friction stir processing on
mechanical properties of the cast aluminum alloys A319 and A356‟ , ScriptaMaterialia, Vol. 53, pp. 201-206.
8. S.Kailainathan, S.KalyanaSundaram, K.Nijanthan, 2014, “Influence of Friction Stir Welding Parameter on
Mechanical Properties in Dissimilar (AA6063-AA8011) Aluminium Alloys”, International Journal of
Innovative Research in Science, Engineering and Technology Vol. 3, Issue 8, August 2014.
9. ShalinP.Marathe, MahantFenilkumarSanjaykumar, DeladaMayursinhDilipsinh, KharadiFaiyazAnwarhusain,
2014, “Experimental analysis of the weld strength in friction stir welding (FSW) of different grades of
aluminum alloy using different tool geometry” International Journal of Mechanical engineering and
Technology, Volume 5, Issue 4, April - 2014.
10. ShrikantG.Dalu, M. T. Shete, 2013, “Effect of various process parameters on friction stir welded joint: a
review” International Journal of Research in Engineering and Technology, Volume: 02 Issue: 12, Dec-2013.
11. Zhang H, Lin S.B, Feng J.C, 2006, “Defects formation procedure and mathematical model for defect free
friction stir welding of magnesium alloy, Materials and Design, 27, 805-809.
12. Zhang Z. and Zhang H.W. (2007) „Numerical studies on effect of axial pressure in friction stir welding‟ ,
Science and Technology of Welding and Joining, Vol.12, No.3, pp. 226-248.

11100

View publication stats