FSW Report

EXPERIMENTAL ANALYSIS OF FRICTION STIR WELDED JOINTS OF
ALUMINUM PLATES
A Thesis
Presented to the faculty of the Department of Mechanical Engineering
California State University, Sacramento
Submitted in partial satisfaction of

the requirements for the degree of
MASTER OF SCIENCE
in
Mechanical Engineering
by
Khaja Muneer Ahmed Mohammed
FALL
2017
© 2017
ALL RIGHTS RESERVED
ii
ALUMINUM PLATES
A Thesis
by
Approved by:
__________________________________, Committee Chair

Akihiko Kumagai, Ph.D.
__________________________________, Second Reader

Kenneth S. Sprott, Ph.D.
____________________________
Date
iii
Student: Khaja Muneer Ahmed Mohammed
I certify that this student has met the requirements for format contained in the University format
manual, and that this thesis is suitable for shelving in the Library and credit is to be awarded for
the thesis.
__________________________, Graduate Coordinator ___________________

Troy Topping, Ph.D. Date
Department of Mechanical Engineering
iv
Abstract
of
ALUMINUM PLATES
by
Welding is the process of creating a high-strength joint between two workpieces.
Welding makes use of a number of techniques or processes, including melting base
metal and loading it with filler material, using electron beams, utilizing lasers etc. One
of the most recent welding techniques is friction stir welding (FSW).
Friction stir welding is a joining process in which a non-consumable rotating tool
plunges between workpieces which are rigidly fixed with clamps and moves along the
join to be welded.
Workpieces composed of aluminum 6061 with a size of 2 x 6 in and a thickness of
0.125 in were selected. Aluminum workpieces were joined by friction stir welding with
the tool spindle speed being varied from 800 rpm to 1200 rpm, and the tool feed rate
being varied from 4.4 in/min. to 8 in/min. The experiments were conducted using a
Megastir E20261 FSW tool.
v
Analysis of the workpieces was undertaken by testing the tensile strengths of the
welded joints. Variations in the strength of the weld joints associated with diverse
parameters is discussed.
_______________________, Committee Chair

Akihiko Kumagai, Ph.D.
_______________________
Date
vi
ACKNOWLEDGEMENTS
I would like to thank Professor Akihiko Kumagai for his interest in the topic I selected
for this thesis. I would also like to express my sincere gratitude to him for his continuous
support during my time at California State University, Sacramento.
Next, I would like to thank all the professors for their guidance and studies.
Finally, I would like to thank my parents, whose support and understanding have made
me what I am today.
vii
TABLE OF CONTENTS
Page
Acknowledgements ................................................................................................................. vii
List of Tables ............................................................................................................................ x
List of Figures .......................................................................................................................... xi
Chapter
1. INTRODUCTION……………………………………………………………………….. 1
1.1 What is Friction Stir Welding? .............................................................................. 1
1.2 Principle of Operation ............................................................................................. 1
2. BACKGROUND ................................................................................................................ 4
2.1 Weld Materials ....................................................................................................... 4
2.2 FSW Tool ............................................................................................................... 4
2.3 Tool Materials ........................................................................................................ 5
2.4 FSW Tool Material Characteristics ....................................................................... 7
2.5 Tool Geometry ....................................................................................................... 7
2.6 Advantages of FSW ............................................................................................... 8
3. EXPERIMENTAL SETUP ................................................................................................. 9
3.1 Workpiece .............................................................................................................. 9
3.2 Tool ...................................................................................................................... 11
3.3 Milling Machine ................................................................................................. 12
3.4 Clamping and Fixtures .......................................................................................... 13
3.5 Working Parameters............................................................................................. 15
3.6 Tilting Angle ........................................................................................................ 17
viii
3.7 Experimental Procedure ....................................................................................... 17
3.8 Tensile Test .......................................................................................................... 20
4. RESULTS AND DISCUSSION .................................................................................. 22
4.1 Tensile Test Results ............................................................................................. 22
4.2 Ultimate Tensile Strength .................................................................................... 34
4.3 Variation in Ultimate Tensile Strength ................................................................ 36
5. CONCLUSIONS AND FUTURE WORK ................................................................. 40
5.1 Conclusion ........................................................................................................... 40
5.2 Future Work ......................................................................................................... 40
References ............................................................................................................................... 42
ix
LIST OF TABLES
Tables Page
1. Tool material selection for different weld materials .. .………………………………. 6
2. Tool material for different alloys of aluminum. ......... .………………………………. 6
3. Chemical compositions of the aluminum plates. ...... .………………………………. 10
4. Mechanical and physical properties of aluminum plates. .. …………………………. 11
5. Dimensions of friction stir welding tool. ........................... …………………………. 12
6. Different parameters for the experiments ........................... ………………………….16
7. Tensile strength of the samples for 800 rpm and 3.5 in/min…………………. .......... 23
8. Tensile strength of the samples for 800 rpm and 4 in/min……………… ............. …. 24
9. Tensile strength of the samples for 900 rpm and 4.5 in/min……………… .......... …. 26
10. Tensile strength of the samples for 900 rpm and 5 in/min……………… ............. …. 27
11. Tensile strength of the samples for 1000 rpm and 5 in/min……………… ........... …. 28
12. Tensile strength of the samples for 1000 rpm and 6 in/min……………… ........... …. 29
13. Tensile strength of the samples for 1100 rpm and 6.5 in/min……………… ........ …. 30
16. Tensile strength of the samples for 1200 rpm and 8in/min……………… ............ …. 33
17. Tensile strengths with respect to parameters and average tensile strength……… . … 34
18. Tensile strengths and magnitude difference between the center pieces…………… . . 37
x
LIST OF FIGURES
Figures Page
1. Friction stir welding operating principle..……………………………………………...3
2. Friction Stir welding tool from Megastir .................... .………………………………. 5
3. Dimensions of aluminum work piece sample. ................. ……………………………. 9
4. High-speed steel tool from Megastir...................................... ………………………..11
5. Solidworks model of Bridgeport Table base plate. ………….………………………. 12
6. Bridgeport series I V2XT CNC milling machine. ............. …………………………. 13
7. Aluminum plates on the iron base plates…………………………………………….. 14
8. Aluminum plates with iron base plate fixed on Bridgeport table……………………. 14
9. Tool tilt angle. ........................................………….…………………………………. 17
10. Aluminum plates after welding at 900 rpm spindle speed and 4.5 in/min ..... ………. 19
11. Aluminum plates after welding at 1200 rpm spindle speed and 7.5 in/min.….…… ... 19
12. Samples of work piece after cut into 4 pieces with shear.…………………………… 20
13. Tensile tester setup.............…………………………………………………………...21
14. Samples showing the welding gaps at the start and end of the workpiece… . ……….22
15. Tensile strength graph for 800 rpm and 3.5 in/min.……………………… ... ……….24
16. Tensile strength graph for 800rpm and 4 in/min.…………………………… .... ……25
17. Tensile strength graph for 900 rpm and 4.5 in/min .. ………………………………..26
18. Tensile strength graph for 900 rpm and 5 in/min ...... ……………………………….27
19. Tensile strength graph for 1000 rpm and 5 in/min ……… ..... ………………………28
21. Tensile strength graph for 1100 rpm and 6.5 inch/min ……… .. ……………………30
xi
22. Tensile strength graph for 1100 rpm and 7.5 in/min ………… .. ……………………31
23. Tensile strength graph for 1200 rpm and 7.5 in/min ………… .. ……………………32
25. Contour graph of spindle speed, feed rate vs tensile strength.………………… ... … 35
26. Contour graph of spindle speed, feed rate vs magnitude difference .. ………………38
xii
1
Chapter 1. INTRODUCTION
1.1 What is Friction Stir Welding?
Friction stir welding (FSW) is a solid-state welding technique invented at The Welding
Institute (TWI) in 1991. The friction stir welding process operates without melting the
workpieces. It operates slightly below the solidus temperatures of the metals being
joined. Since its invention in 1991, continuous research has been done by industries and
researchers to improve the technique.
Friction stir welding is a joining process in which a non-consumable rotating tool plunges
into workpieces which are rigidly fixed with clamps and fixtures, and moves along the
join to be welded. The cylindrical rotating tool used in FSW has a profiled threaded or
unthreaded probe of a length less than the weld depth, protruding from the tool shoulder.
The FSW process is started by plunging a rotating tool into the joint of the workpiece
metals until the shoulder contacts the upper surface of the metal workpiece. As the tool
moves along the joint, heat is generated by the friction action of the tool shoulder against
the metal workpiece. [1]
1.2 Principle of Operation
Friction stir welding consists of four important phases:
1) During the penetrating phase or plunging phase, the rotating tool approaches the
surface of the metal workpiece and penetrates into the metal generating the initial heat.
2
2) The dwelling phase involves reaching the operating temperature which is necessary to
begin the welding until a constant downward force is achieved between the tool and
workpiece, which creates the friction energy between them. This process continues until
the pressure force between the FSW tool and the surface of the metal workpiece begins to
gradually decrease, which indicates that the temperature required to commence welding
has been achieved.
3) The welding phase involves complex thermo-mechanical activity. The constant
frictional energy generates high temperatures which soften the material at the joining of
the plates. The material of both the workpieces at the joining is mixed together with the
help of the pin as the tool moves forward in the welding direction.
4) The final phase is the retracting phase. When the tool reaches the end of the joining
line of the workpieces, it retracts vertically. The operating principles of the FSW process
are illustrated in Figure 1. [2]

3
Figure 1. Friction stir welding operating principle [2]

4
Chapter 2. BACKGROUND
2.1 Weld Materials
A variety of materials, from low melting point metals to high melting point metals, can
be successfully welded with the friction stir welding technique. A wide range of metals,
including aluminum, aluminum alloys, copper, copper alloys, brass, magnesium alloys,
titanium alloys, nickel alloys, silver and gold, can be welded with FSW. FSW can
combine not only similar metals, but also dissimilar metals. [1]
2.2 FSW Tool
An FSW tool has a cylindrical shoulder with a profiled probe or pin. Figure 2 illustrates
the most common FSW tool. The FSW tool’s angular velocity is measured in revolutions
per minute (rpm), also known as spindle speed. The translational velocity of the tool
along the weld joint of the workpieces is the feed rate of the tool measured in inches per
minute (in/min.) or millimeters per second (mm/s). Feed rate is also known as traverse
speed.
Three important forces come into action in the friction stir welding process. As shown in
Figure 1, the force acting in the x-axis is known as the side force (Fx), the force acting in
the welding direction or y-axis is known as the traverse force (Fy), and the force acting in
the z-axis due to the tool is known as the axial force or downward force (Fz).
5
Figure 2 Friction stir welding tool from Megastir [3]
2.3 Tool Materials
Several tool materials have been used in the FSW process. The selection of an
appropriate material for the tool is based upon the type of material to be welded. Table 1
shows the different types of tool materials used to weld different types of materials. [4]
6
Table 1. Tool material selection for different weld materials [4]
Tool material Suitable weld material
Tool steels Aluminum alloys, aluminum metal matrix composites (AMCs)
and copper alloys
WC –Co Aluminum alloys, mild steel
Tungsten carbide
Nickel alloys Copper alloys
WC composite Aluminum alloys, low-alloy steel and magnesium alloys,
titanium alloys
Tungsten alloys Titanium alloys, stainless steel and copper alloys
PCBN Copper alloys, stainless steels and nickel alloys
The tool material used for different alloys of aluminum is set out in Table 2 below.
Table 2. Tool material for different alloys of aluminum [4]
Tool material Aluminum Alloy
H13 Steel 6061-T6 Al alloy
High Carbon Steel 7020-T6 Al alloy
H13 Steel 5754 Al
Tool steel A319 and A413 Al

7
2.4 FSW Tool Material Characteristics
To produce a high quality FSW joint, the tool material selection must be done properly.
According to a study conducted by Zhang et al [5], the following characteristics must be
considered when selecting an appropriate tool material for FSW:
• Resistance to wear.
• No harmful reactions with the weld metal or work piece material.
• High strength, dimensional stability at high temperatures.
• Very high creep resistance at elevated temperatures.
• Good thermal fatigue strength to resist many repeated experiments.
• Good fracture toughness to resist the damage during FSW processes of plunging and
traversing of the tool.
• Low coefficient of thermal expansion.
• Good machinability for the manufacture of complex features on the shoulder and
probe.
2.5 Tool Geometry
The geometry of the FSW tool also plays a vital role in the welding process. According to
a study conducted by Cavaliere, De Santis and Pannela [6], important geometrical factors
affecting the process are the shoulder diameter and pin design, particularly its
geometrical shape and size. The distribution of melted soft material in the workpiece does
not only depend on the rotation and linear motion of the FSW tool, but also on the shape
and size of the tool. Tool geometry influences the rate of heat generation, forces acting in
the process, torque, and the thermo-mechanical domain of the FSW tool.
8
2.6 Advantages of FSW
The advantages of friction stir welding are: [7]
• The process is environmentally friendly, since no fumes and spatter are generated
and no shielding gas is required.
• A non-consumable tool is used.
• Since the weld is obtained in solid phase, gravity does not play any part, hence
the process can be undertaken in any position (vertical, horizontal, overhead or
orbital).
• No grinding, brushing or pickling is required.
• Since the temperature involved in the process is quite low, there is less shrinkage
during solidification.
• No fusion or filler materials are required.
• No oxide removal process is required as in fusion welding.
• The weld obtained using FSW is of high quality, with very good mechanical
properties and a finer microstructure than is achievable using conventional
welding techniques.
• Not only similar but also dissimilar metals can be welded by FSW.
• The process can be automated.

9
Chapter 3. EXPERIMENTAL SETUP
3.1 Workpiece
This experimental analysis of friction stir welding is critical to enabling the integration of
the welding of aluminum material in a wide range of applications in the industrial sector,
and to improve the usage of eco-friendly manufacturing processes. For the following
experiments, two plates of AA 6061-T6511 aluminum with a thickness of 0.125 in were
butt welded by FSW along the joint line indicated in Figure 3. Aluminum plates were
ordered from McMaster Carr. The samples were cut to 2 in in length and 6 in in width.
Figure 3. Dimensions of aluminum workpiece sample
The chemical properties of the aluminum plates utilized in the experiments are set out
below in Table 3.
10
Table 3. Chemical compositions of the aluminum plates [8]
Element % Composition
Aluminum 95.1–98.2 %
Chromium 0.4–0.8 %
Copper 0.05–0.4 %
Iron 0–0.7 %
Magnesium 0.8–1.20 %
Manganese 0–0.15 %
Nickel 0–0.05 %
Silicon 0.4–0.80 %
Titanium 0–0.15 %
Zinc 0–0.25 %
Zirconium 0–0.25 %
Other 0.15 %
The mechanical and physical properties of the workpieces play an important role in many
aspects such as tool material selection and weldability. Table 4 sets out the mechanical
and physical properties of the aluminum plates used in the experiments.

11
Table 4. Mechanical and physical properties of aluminum plates [8]
Yield strength 35000 psi
Hardness Brinell 95
Density 0.1 lbs./cu. in.
Surface resistivity 25 Ohm-Cir Mil/ft
Modulus of elasticity 10.0 ksi × 103
Thermal conductivity 1,160 Btu/hr. × in./sq. ft./°F @ 75° F
Melting point 1080° F
3.2 Tool
The high-speed steel FSW tool from Megastir was used in these experiments.
Figure 4. High-speed steel tool from Megastir.

12
The dimensions of the friction stir welding tool are shown in Table 5.
Table 5. Dimensions of friction stir welding tool
Material High speed steel
Shank diameter 0.75 inches
Shoulder diameter 0.375 inches
Pin length 0.118 inches
Pin features Threaded step spirals
3.3 Milling Machine
The Bridgeport Series I V2XT CNC milling machine was used in the experiments. The
base plate of the Bridgeport table is 42 x 13 in; Figure 5 illustrates the Solidworks model
of the table.
Figure 5. Solidworks model of Bridgeport table base plate

13
Figure 6. Bridgeport series I V2XT CNC milling machine
3.4 Clamping and Fixtures
A 4 x 6 in iron base plate is used to support the aluminum plates. Workpieces are held
together tightly by screws on the iron base plate. Thereafter the aluminum plates and the
iron base plate are fixed on the table of the Bridgeport milling machine with clamps and
fixtures as shown in Figure 8.

14
Figure 7. Aluminum plates on the iron base plate
Figure 8. Aluminum plates with iron base plate fixed on Bridgeport table
15
3.5 Working Parameters
Main parameters to consider:
• Rotation speed or spindle speed
• Welding speed, feed rate or traverse speed
• Axial force or down force
Axial force:
• Axial force varies directly with plunge depth. Axial force increases with an
increase in the plunge depth.
• Axial force decreases when increasin the rotational speed of the tool. This
decrease has two causes:
 The temperature of the workpiece increases with rotational speed as the
material will be softer and require less axial force at a given plunge depth.
 A faster rotating tool or pin removes more material from under the shoulder so
a given plunge depth is obtained with less axial force.
• Axial force should be higher for materials with higher thermal diffusivity because
high thermal diffusivity results in a cooler material ahead of the weld. Thus, a
higher weld speed or feed rate is expected.
After reviewing “Friction stir welding tools” by Rai, De, Bhadeshia and DebRoy [4] and
“Study of Friction stir welding of aluminum” by Wang, Liu and Cao [9], the following
parameters were set for the experiments.

16
Table 6. Different parameters for experiments
Spindle Speed (rpm) Feed rate / Weld Speed / Traverse
Speed (in/min.)
800 rpm 3.5 in/min.
800 rpm 4 in/min.
900 rpm 4.5 in/min.
900 rpm 5 in/min.
1000 rpm 5 in/min.
1000 rpm 6 in/min.
1100 rpm 6.5 in/min.
1200 rpm 8 in/min.

17
3.6 Tilting Angle
The tilting angle of the tool is also an important parameter to consider in FSW. An
improper tilting angle results in defects in the weld. For all the experiments in this thesis,
a 1º constant tool tilt angle was used. The head of the Bridgeport Milling Machine was
rotated 1º so that the tool was angled at 1º in the direction of the weld.
Figure 9. Tool tilt angle
3.7 Experimental Procedure
The steps followed in conducting the experiments were as follows.

18
• Fix the aluminum workpieces to the backing anvil (or the iron base plate) with
screws.
• Clamp the set to the table of the Bridgeport milling machine with clamps and
fixtures.
• Program the spindle speed in accordance with the initial parameters set out in
Table 6.
• Set the travel speed or feed rate. Set the distance of downward tool travel.
• Start the spindle of the Bridgeport Milling machine.
• Plunge the tool into the workpiece until the shoulder touches the surface of the
plates.
• Engage the feed rate or traverse speed of the tool.
• Travel the tool to the end.
• Retract the tool once the weld is completed.
• Stop the spindle.
• Unclamp the fixtures and remove the welded plate.
• Repeat the experiments using the remaining parameters set out in Table 6.
Figure 10 illustrates the appearance of the aluminum plates following friction stir welding
at 900 rpm spindle speed with 4.5 in/min. feed rate. Figure 11 illustrates the appearance
of the aluminum plates following friction stir welding at 1200 rpm spindle speed and 7.5
in/min.
19
Figure 10. Aluminum plates after welding at 900 rpm spindle speed and 4.5 in/min.
Figure 11. Aluminum plates after welding at 1200 rpm spindle speed and 7.5 in/min.
20
3.8 Tensile Test
Each workpiece representing each set of parameters set out in Table 6 was cut into four
pieces, using shear, with a 1.5 in width as shown in Figure 12.
Figure 12. Sample of a workpiece after being cut into four pieces with shears
Following this procedure, the size of each sample was 1.5 in x 4 in with a thickness of
0.03 in, which is the depth of penetration or weld depth. Each sample was then subjected
to a tensile test. Each sample was held in the tensile tester using the grips. The tensile
tester automatically recorded the change in the gauge length, which is the length under
observation, and the displacements between the cross heads.

21
Figure 13. Tensile tester setup [10]
Once the specimen was loaded and fixed between the holding grips, the machine was
started. Then the tensile load on the specimen was gradually increased. During the whole
process, the computer associated with the tensile tester recorded the data. The load,
elongation in inches and time was recorded in CSV datasheets.

22
Chapter 4. RESULTS AND DISCUSSION
4.1 Tensile Test Results
The ultimate loads for the 800 rpm spindle speed and 3.5 in/min. feed rate workpiece are
shown in Table 7. The samples are 1.5 in in length and with a 0.03 in penetration depth of
the weld for the effective weld area.
Figure 14. Samples showing the welding gaps at the start and end of the workpiece
As shown in Figure 14, end pieces 1 and 4 are not completely welded along the joint line
of the two pieces. This is as a result of the tool not being plunged into the pieces at the
very beginning of the plate, and being retracted just before the end of the plate.
Therefore, the analysis is done on pieces 2 and 3, as they are continuously welded.
23
All the samples for the different parameter sets shown in Table 6 were produced in the
same manner.
Table 7. Tensile strength of the samples for 800 rpm and 3.5 in/min.
800 rpm and 3.5in/min. Sample 1 Sample 2 Sample 3 Sample 4
Ultimate load (lbs.) 35.1 732.1 1134.9 77.9
Breaking point (lbs.) 34.0 132.6 825.1 60.6
Ultimate tensile strength (psi) 77.7 16268.88 25220 1731.1

24
Figure 15. Tensile strength graph for 800 rpm and 3.5in/min.
The ultimate loads for the 800 rpm spindle speed and 4 in/min. feed rate workpiece are
set out in Table 8 below.
Table 8. Tensile strength of the samples for 800 rpm and 4 in/min.
800 rpm and 4 in/min. Sample 1 Sample 2 Sample 3 Sample 4
Ultimate load (lbs.) 796 1112.5 418.3 293.4

25
Ultimate tensile strength (psi) 17688.8 24722.2 9295.5 6520
Figure 16. Tensile strength graph for 800 rpm and 4 in/min.
The ultimate loads for the 900 rpm spindle speed and 4.5 in/min. feed rate workpiece are

26
900 rpm and 4.5 in/min. Sample 1 Sample 2 Sample 3 Sample 4
Breaking point (lbs.) 606.1 604 743 142.9
Ultimate tensile strength (psi) 24177.7 21471.1 24746.6 12297.7
Figure 17. Tensile strength graph for 900 rpm and 4.5 in/min.
27
Breaking point (lbs.) 429.9 688.4 518 154
Ultimate tensile strength (psi) 10320 23173.3 18302.2 17102.2
28
1000 rpm and 5 in/min. Sample 1 Sample 2 Sample 3
Ultimate load (lbs.) 841.9 946.3 1064.3
Breaking point (lbs.) 439.7 272 422
Ultimate tensile strength (psi) 18708.8 21028.8 23651.1
29
Ultimate load (lbs.) 764.4 1063 1043.6 739.1
30
The ultimate loads for the 1100 rpm spindle speed and 6.5 in/min. feed rate workpiece
are set out below in Table 13.
Ultimate tensile strength (psi) 22033.3 25560 24848.8 20291.1
31
are set out in Table 14 below.
Ultimate load (lbs.) 482 1025.6 1057.6 938.2
Breaking point (lbs.) 125.9 202 212.9 387.2
32
are set out in Table 15 below.
Ultimate tensile strength (psi) 21255.5 23680 22486.6 21502.2
33
Breaking point (lbs.) 583.2 173.7 197 179.3
34
4.2 Ultimate Tensile Strength
Only the center pieces were taken into consideration. The ultimate tensile strengths of the
center pieces of all of the plates are set out below. The average tensile strengths of the
center pieces have been calculated.
Table 17. Tensile strengths with respect to parameters and average tensile strength
Parameter Piece 2 UTS (psi) Piece 3 UTS (psi) Average UTS (psi)
800 rpm 3.5 in/min. 16268.88 25220 20744.4
800 rpm 4 in/min. 24722.2 9295.5 17008.85
900 rpm 4.5 in/min. 21471.1 24746.6 24462.15
900 rpm 5 in/min. 23173.3 18302.2 20737.75
1000 rpm 5 in/min. 21028.8 23651.1 22339.55
1000 rpm 6 in/min. 23622.2 23191.1 23406.65
1100 rpm 6.5 in/min. 25560 24848.8 25204.4
1100 rpm 7.5 in/min. 22791.1 23502.2 23146.65
1200 rpm 7.5 in/min. 23680 22486.6 23083.3
1200 rpm 8 in/min. 19257.7 22097.7 20677.7

35
The results indicate that the tensile strength of FSW for aluminum plates increased as the
spindle speed and feed rate were increased. The maximum tensile strength was achieved
at 1100 rpm and an 8 in/min. feed rate, after which the tensile strength declined in inverse
proportion to increases in the spindle speed and feed rate.
Figure 25. Contour graph of spindle speed and feed rate vs tensile strength
In Figure 25, the dark orange-red region represents high tensile strength, whereas the
dark blue-green region indicates low to medium tensile strength.

36
Figure 25 illustrates that the highest tensile strength is achieved for spindle speeds in the
region of 1050 to 1150 rpm and feed rates of 6 to 7 in/min. Low spindle speeds of 800 to
1000 rpm and feed rates of 3 to 5.5 in/min. resulted in low tensile strengths due to
insufficient heat generation by the tool on the surface. Low pressure acting on the surface
resulted in low tensile strengths of the aluminum plates.
Spindle speeds from 1050 to 1150 rpm and feed rates of 6 to 7 in/min. created optimum
heat generation resulting in high tensile strengths. When the spindle speeds are further
increased to more than 1150, and feed rates exceed 7 in/min., excessive heat is generated,
resulting in lower tensile strengths.
4.3 Variation in Ultimate Tensile Strength
Variations in the ultimate tensile strength of the plates is important in the manufacturing
process. Consistent tensile strengths indicate that the process is stable. Excessive
variation in the tensile strengths would indicate that the process is unstable. If the
difference in magnitude of tensile strength between the center pieces is low, the process
can be considered stable and reliable. If the difference in magnitude is high, the process is
unstable and unreliable.
The difference in magnitude between the tensile strengths of the pieces is set out in
Table 18 below.
37
Table 18. Tensile strengths and magnitude difference between the center pieces
Parameter Piece 2 UTS Piece 3 UTS Magnitude difference
(psi) (psi) (psi)
800 rpm 3.5 in/min. 16268.88 25220 8951.12
800 rpm 4 in/min. 24722.2 9295.5 15427.7
900 rpm 4.5 in/min. 21471.1 24746.6 3275.5
900 rpm 5 in/min. 23173.3 18302.2 4871.1
1000 rpm 5 in/min. 21028.8 23651.1 2622.3
1000 rpm 6 in/min. 23622.2 23191.1 431.1
1100 rpm 6.5 25560 24848.8 711.2
in/min.
1100 rpm 7.5 22791.1 23502.2 711.1
in/min.
1200 rpm 7.5 23680 22486.6 1193.4
in/min.
1200 rpm 8 in/min. 19257.7 22097.7 2840

38
Figure 26. Contour graph of spindle speed, feed rate vs magnitude
In Figure 26, the dark blue area represents the low magnitude difference in the tensile
strength of the center pieces, which means that the process is stable and produced
consistent tensile strength throughout the welding. The orange-red area represents a high
magnitude difference in the tensile strength of the center pieces, which indicates that the
process is unstable and produces inconsistent tensile strengths throughout the welding.
Figure 26 illustrates that a low magnitude difference in tensile strength is achieved at

39
spindle speeds of 1050–1150 rpm and feed rates of 5.5–7.5 in/min. These parameters
produced stable and consistent tensile strengths. A high magnitude difference in tensile
strengths is observed at spindle speeds of 800–950 rpm and feed rates of 3.5–5 in/min.,
which produced inconsistent tensile strengths.

40
Chapter 5. CONCLUSION AND FUTURE WORK
5.1 Conclusion
In this study, Aluminum plates AA 6061-T6511 1.5 x 1.5 in of a thickness of 0.125 in
were butt welded by FSW, with varying parameters of spindle speeds and feed rates of
800 rpm 3.5in/min., 800 rpm 4in/min., 900 rpm 4.5in/min., 900 rpm 5 in/min., 1000 rpm
5in/min., 1000 rpm 6in/min., 1000 rpm 6.5in/min., 1100 rpm 6.5in/min., 1100 rpm
7.5in/min., 1200 rpm 7.5in/min. and 1200 rpm 8in/min. Megastir’s high speed steel FSW
tool was used.
It is observed that the greatest tensile strength is achieved using spindle speeds of 1050 to
1150 rpm and feed rates of 6 to 7 in/min., particularly at 1100 rpm and 6.5 in/min.
Aluminum plates with a high tensile strength are produced.
Stable and consistent tensile strengths are achieved using spindle speeds of 1050 to 1150
rpm and feed rates of 5.5 to 7.5 in/min., particularly at 1100 rpm and 6.5in/min., and
1100 rpm and 7.5 in/min.
5.2 Future work
In this study, only the spindle speed and feed rate parameters were varied to conduct the
experiments. Downward force was not measured. Nevertheless, downward force is also
41
an important parameter to be considered. Further studies could be conducted on the
manner in which downward force affects the parameters and tensile strengths.
A number of recommendations for future experiments are set out below.
• Add load cells to the setup to measure the downward force during welding.
• Vary the downward force parameter for the experiments.
• Vary the tilting angle from 1º to 2º and 3º to establish how the tilting angle affects
the tensile strengths.
• Study the microscopic structure of the welds.
• Conduct the experiments using different FSW tools or different tool geometries
and different tool pins, such as cylindrical, square, or threaded cylindrical ones.
• Extend the experiments to investigate the welding of dissimilar materials.

42
References
[1] Thomas, WM; Nicholas, ED; Needham, JC; Murch, MG; Temple-Smith, P; and
Dawes, J. “Friction-stir butt welding.” GB Patent No. 9125978.8, International
Patent Application No. PCT/GB92/02203, (1991)
[2] Miličić, M; Gladović, P; Bojanić, R; Savković, T; and Stojić, N. “Friction Stir
Welding FSW) Process of Copper Alloys.” METABK VOL. 55 No. 1 (2016): pp.
107–110.
[3] Products and Services Catalog from http://www.slb.com/services/megastir.aspx
[4] Rai, R; De, A; Bhadeshia, HKDH; and DebRoy, T. “Friction Stir Welding Tools.”
Science and Technology of Welding and Joining VOL. 16 No. 4 (2011): pp. [insert
page numbers].
[5] Zhang, YN; Cao, X; Larose, S; and Wanjara, P. “Review of tools for friction stir
welding and processing.” Canadian Metallurgical Quarterly VOL. 51 No. 3
(2012): [insert page numbers].
[6] Cavaliere, P; De Santis, A; and Pannela, F. “Effect of welding parameters on
mechanical and microstructural properties of dissimilar AA6082–AA2024 joints
produced by friction stir welding.” Materials & Design VOL. 30 No. 3 (2009): pp.
[insert page numbers].
[7] Sidhu, MS and Chatha, SS. “Friction Stir Welding – Process and its Variables: A
Review.” International Journal of Emerging Technology and Advanced
Engineering VOL. 2 No. 12 (2012): pp. [insert page numbers].

43
[8] https://www.mcmaster.com/#8975K582
[9] Wang, D; Liu, S; and Cao, Z. “Study of friction stir welding of aluminum.” Journal
of Materials Science VOL. 39 No. 5 (2004), pp. [insert page numbers].
[10] http://www.engineeringarchives.com/les_mom_tensiletest.html

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EXPERIMENTAL ANALYSIS OF FRICTION STIR WELDED JOINTS OF

Presented to the faculty of the Department of Mechanical Engineering

California State University, Sacramento

Submitted in partial satisfaction of

Khaja Muneer Ahmed Mohammed

Khaja Muneer Ahmed Mohammed

ALL RIGHTS RESERVED

Khaja Muneer Ahmed Mohammed

__________________________________, Committee Chair

__________________________________, Second Reader

__________________________, Graduate Coordinator ___________________

Department of Mechanical Engineering

EXPERIMENTAL ANALYSIS OF FRICTION STIR WELDED JOINTS OF

Khaja Muneer Ahmed Mohammed

Welding is the process of creating a high-strength joint between two workpieces.

Welding makes use of a number of techniques or processes, including melting base

of the most recent welding techniques is friction stir welding (FSW).

Friction stir welding is a joining process in which a non-consumable rotating tool

Workpieces composed of aluminum 6061 with a size of 2 x 6 in and a thickness of

Megastir E20261 FSW tool.

_______________________, Committee Chair

support during my time at California State University, Sacramento.

Acknowledgements ................................................................................................................. vii

List of Tables ............................................................................................................................ x

List of Figures .......................................................................................................................... xi

1.1 What is Friction Stir Welding? .............................................................................. 1

1.2 Principle of Operation ............................................................................................. 1

2.1 Weld Materials ....................................................................................................... 4

2.2 FSW Tool ............................................................................................................... 4

2.3 Tool Materials ........................................................................................................ 5

2.4 FSW Tool Material Characteristics ....................................................................... 7

2.5 Tool Geometry ....................................................................................................... 7

2.6 Advantages of FSW ............................................................................................... 8

3. EXPERIMENTAL SETUP ................................................................................................. 9

3.1 Workpiece .............................................................................................................. 9

3.2 Tool ...................................................................................................................... 11

3.3 Milling Machine ................................................................................................. 12

3.4 Clamping and Fixtures .......................................................................................... 13

3.5 Working Parameters............................................................................................. 15

3.6 Tilting Angle ........................................................................................................ 17

3.8 Tensile Test .......................................................................................................... 20

4. RESULTS AND DISCUSSION .................................................................................. 22

4.1 Tensile Test Results ............................................................................................. 22

4.2 Ultimate Tensile Strength .................................................................................... 34

4.3 Variation in Ultimate Tensile Strength ................................................................ 36

5. CONCLUSIONS AND FUTURE WORK ................................................................. 40

5.1 Conclusion ........................................................................................................... 40

5.2 Future Work ......................................................................................................... 40

1. Tool material selection for different weld materials .. .………………………………. 6

2. Tool material for different alloys of aluminum. ......... .………………………………. 6

3. Chemical compositions of the aluminum plates. ...... .………………………………. 10

4. Mechanical and physical properties of aluminum plates. .. …………………………. 11

5. Dimensions of friction stir welding tool. ........................... …………………………. 12

6. Different parameters for the experiments ........................... ………………………….16

1. Friction stir welding operating principle..……………………………………………...3

2. Friction Stir welding tool from Megastir .................... .………………………………. 5

3. Dimensions of aluminum work piece sample. ................. ……………………………. 9

4. High-speed steel tool from Megastir...................................... ………………………..11

5. Solidworks model of Bridgeport Table base plate. ………….………………………. 12

6. Bridgeport series I V2XT CNC milling machine. ............. …………………………. 13

7. Aluminum plates on the iron base plates…………………………………………….. 14

8. Aluminum plates with iron base plate fixed on Bridgeport table……………………. 14

9. Tool tilt angle. ........................................………….…………………………………. 17

________, Graduate Coordinator _