Investigation of Mechanical Behavior of an AA5083/AA6061 Friction Stir Welding Using Modal analysis

Solid-state joining is used for welding similar or dissimilar materials due to its many advantages (avoiding fusion and formation of a thick intermetallic layer). Determination of process parameters (feed rate and rotation speed) and tool geometry (shoulder and pin) is significant in friction stir welding in order to obtain adequate weld quality. The experiments were performed using three process parameters: feed rate (mm/min), rotation speed (rpm), and pin geometry for friction stir welding of Al5083 and Al6061. Eighteen experiments were performed by varying the process parameters and mechanical tests (microhardness and tensile measurements) have been carried out to determine the weld quality. When the results were evaluated according to ultimate strength, the best result (198.5 MPa) was obtained in triangle pin geometry, 1250 rpm, and 100 mm/min parameters. The similarity was determined in the microhardness results. Effects of tool geometry, feed rate, and rotation speed on the vibration properties and weld quality are also investigated experimentally. The effects of the FSW parameters used are discussed using vibration analysis.