Evaluation of axial force, tool torque and weld quality of friction stir welded dissimilar 6061/5083 aluminum alloys

In this research, the welding parameters of the friction stir welding (FSW) of dissimilar 6061/5083 aluminum alloys were optimized, and the significance of each welding parameter was determined. The effect of welding parameters on weld quality was obtained by testing the mechanical properties of welded joints. The influences of welding parameters on material mixing were studied through metallography and microhardness. The data acquisition system of axial force and tool torque was designed, and the relationships between the data and welding parameters were analyzed. The results showed that the materials were not sufficiently mixed and thus void type defects were formed at higher traverse speeds. The optimum welding parameters, namely rotational speed, traverse speed, and plunge depth were 2400 rpm, 1200 mm/min, and 0.25 mm, respectively.