CHAPTER SIX

CONCLUSIONS AND REFERENCES

6.1. Conclusions:

In this investigation, an attempt has been made to determine the ability of forming a
butt joint by means of friction stir welding of AA2024-T3 Aluminum alloy plates, and
study the effect of tool rotational speed, tool welding speed and shoulder diameter on
the tensile characteristics of the friction stir welded joint of AA2024-T3 Aluminum
plates. From this investigation, the following important conclusions are derived:

1) Friction stir welding joints of AA2024 aluminum alloy were successfully

attained.
2) The tool rotational speed was found to be the most effective parameter on the
friction stir welding of the joints.
3) The joint made with the experiment number 6 in Table.4.8.exhibited the
highest tensile strength and had no defects.
4) The optimum tool shoulder diameter giving superior tensile properties was
found 18 mm.
5) The optimum tool rotational speed which produced defect-free joint was found
to be 700 RPM.

6.2. Recommendations:

1) Use an assistance method during the process of friction stir welding to provide
an extra heat source such as laser assisted and electrically assisted FSW.
2) Use the ultrasonic vibrations to provide softening to the workpiece during the
welding process.
3) Use other parameters such as tool pin profile, tilt angle and plunge depth
which have been proved to have a significant effect on the FSW based on
literature review.
4) Use software to determine the optimum values of the parameters being studied
in the investigation.
 5) Use a suitable cutting technique of the workpiece sheet to provide smooth and
high quality surface to achieve perfect contact between the two plates before
welding.
6) The tool material should have high hardness, hot hardness, fracture toughness
and wear resistance.
7) Ensuring a very good fixation of the plates during the welding process to
avoid any defects.

6.3. References:

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speed of the tool on the formation of the friction stir processing zone in AA2219
aluminum alloy‖ Materials science and engineering 27th of December 2006.

[3] K. Elangovan, V. Balasubramanian and M. Valliappan, ―Effect of Tool Pin Profile

and Tool Rotational Speed on Mechanical Properties of Friction Stir Welded AA6061
Aluminum Alloy.‖ Materials and Manufacturing Processes 2008.

[4] M. K. Kulekci, A. Şik and E. Kaluç, ―Effects of tool rotation and pin diameter on
fatigue properties of friction stir welded lap joints.‖ Springer-Verlag London Limited
2006.

[5] T. S. Mahmoud, A. M. Gaafer and T. A. Khalifa, ―Effect of tool rotational and

welding speeds on microstructural and mechanical characteristics of friction stir
welded A319 cast Al alloy‖. Materials Science and Technology 2008.
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and rotational speed for increased speed during friction stir welding of AA2024-T3.‖
Journal of manufacturing processes 2014.

[7] J. Yan, M. A. Sutton and A. P. Reynolds, ―Process–structure–property

relationships for nugget and heat affected zone regions of AA2524–T351 friction stir
welds.‖ Science and Technology of Welding and Joining 2005.

[8] L. Q. Lia and H. J. Liu, ―Effects of tool rotation speed on microstructures and
mechanical properties of AA2219-T6 welded by the external non-rotational shoulder
assisted friction stir welding.‖ Materials and Design 2012.

[9] H.J. Liu, J.C. Hou and H. Gou, ―Effect of welding speed on microstructure and
mechanical properties of self-reacting friction stir welded 6061-T6 aluminum alloy.‖
Materials and Design 2013.

[10] M. N. James, D. G. Hattingh and G. R. Bradley, ―Weld tool travel speed effects
on fatigue life of friction stir welds in 5083 Aluminum.‖ International Journal of
Fatigue 2003.

[11] H.J. Liu, H.J. Zhang and L. Yu, ―Effect of welding speed on microstructures and
mechanical properties of underwater friction stir welded 2219 aluminum alloy.‖
Materials and Design 2010.

[12] T. Sakthivel, G.S. Sengar and J. Mukhopadhyay, ―Effect of welding speed on

microstructure and mechanical properties of friction-stir-welded aluminum.‖
Springer-Verlag London Limited 2008.
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welding speed on the formation of friction stir processing zone in AA2219 Aluminum
alloy.‖ Journal of Materials Processing Technology 2008.

[14] P. Cavaliere, A. Squillace and F. Panella, ―Effect of welding parameters on

mechanical and microstructural properties of AA6082 joints produced by friction stir
welding.‖ Journal of Material Processing Technology 2008.

[15] K. Elangovan and V. Balasubramanian, ―Influences of tool pin profile and tool
shoulder diameter on the formation of friction stir processing zone in AA6061
Aluminum alloy.‖ Materials and Design 2008.

[16] K. Kumar, S. V. Kailas and T. S. Srivatsan, ―Influence of Tool Geometry in

Friction Stir Welding.‖ Materials and Manufacturing Processes Jan 2008.

[17] M. Mehta, A. Arora, A. De and T. Debroy, ―Tool Geometry for Friction Stir
Welding—Optimum Shoulder Diameter.‖ Metallurgical and Materials Transactions A
– Springer September 2011.

[18] N. Z. Khan, Z. A. Khan and A. N. Siddiquee, ―Effect of shoulder diameter to pin

diameter (D/d) ratio on tensile strength of friction stir welded 6063 Aluminum alloy.‖
Materials Today: Proceedings 2 (2015).

[19] G. Padmanaban and V. Balasubramanian, ―Selection of FSW tool pin profile,

shoulder diameter and material for joining AZ31B magnesium alloy – An
experimental approach.‖ Materials and Design 2009.
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welding.‖ 9th of April 2014.

[21] N. A. Muhammad and C.S. Wu, ―Ultrasonic vibration assisted friction stir
welding of Aluminum alloy and pure copper.‖ Journal of Manufacturing Processes
2014.

[22] K. Park, DEVELOPMENT AND ANALYSIS OF ULTRASONIC ASSISTED

FRICTION STIR WELDING PROCESS, 2014.

[23] S. L. Campanelli, G. Casalino, C. Casavola and V. Moramarco, ―Analysis and

Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of
Aluminum Alloy.‖ 18 December 2013.

[24] Y.F. Sun, Y. Konishi, M. Kamai, H. Fujii, ―Microstructure and mechanical

properties of S45C steel prepared by laser-assisted friction stir welding.‖

[25] Xun Liu Shuhuai Lan Jun Ni, ―Electrically assisted friction stir welding for
joining Al6061 to TRIP 780 steel.‖ Journal of Materials and Processing
Technology, December 2014.

[26] T. G. Santosa, R.M. Mirandaa, P. Vilac¸ ―Friction Stir Welding assisted by

electrical Joule effect.‖ Journal of Materials Processing Technology, 6 March 2014.

[27] M. A. Wahid, Z. A. Khan and A. N. Siddiquee, ―Review on underwater friction

stir welding: A variant of friction stir welding with great potential of improving joint
properties‖. 18 April 2018.