A COMPREHENSIVE EXPERIMENTAL STUDY ON THE FRICTION STIR WELDING PROCESS FOR JOINING AA6063 ALUMINIUM ALLOY

Despite the widespread use of welding in manufacturing and structural applications, inconsistencies in weld quality remain a significant challenge. Factors such as material flow and heat distribution during the welding process play a critical role in determining the integrity of the weld. This study focuses on using Friction Stir Welding (FSW) to join AA6063 aluminum alloy using a milling machine with a vertical spindle attachment. Four different trials, labeled T1, T2, T3, and T4, are conducted, each with varying welding speeds and tool rotational speeds to explore the impact of these parameters on the weld quality. The tools used in these trials have different threading: M12×1.75 and M8×1, and each has a distinct shoulder diameter. This variation in tool design affects the surface area in contact with the workpiece during welding, which in turn influences heat generation and material flow. The primary goal of these experiments is to assess the weld quality based on several key factors, such as the presence of fractures, porosity, and blow holes, as well as the effect of heat on the grain structure in the welded material, particularly in the heat-affected zone (HAZ). The study demonstrates the milling machine's capability for performing FSW on aluminum alloys, an important aspect for industrial applications where precision and integrity are crucial. The welded joints undergo tensile testing according to ASTM E407-2007 standards. The results show a maximum weld penetration of 8.71 mm, with no cracks or blow holes observed in the joints, indicating high-quality welds. Additionally, the heat-affected zone is visible, reflecting the thermal effects on the material due to the welding process. Overall, the study provides valuable insights into optimizing FSW parameters and highlights the effectiveness of using a milling machine for aluminum alloy welding.