This document summarizes a research project on friction stir welding (FSW) of dissimilar aluminum alloys. The objectives were to design an FSW weld for joining different aluminum series in a 3G position, evaluate the best welding parameters such as rotational and transverse speed, and analyze tensile strength properties. FSW was performed using different transverse speeds and a fixed rotational speed. Tensile testing showed the highest strength was achieved with a transverse speed of 86mm/min, meeting the project's objectives.

1. Abstract - Friction Stir Welding (FSW) was introduced in 1991 by TWI in Cambridge, England, as a solid-state metal
joint process by which alternative way for welding structure of materials such as titanium, lead, copper and aluminum. The
unique properties of Friction Stir Welding make possible some completely new structural designs with significant impact to
shipbuilding industries. This research paper was carried out in order to achieve the following objectives which were to make a
weld design for FSW dissimilar aluminum series joining at 3G positon, to evaluate the best parameters for 3G position of FSW
process such as the optimum for rotational speed and transverse speed. Lastly to conduct and analyses the tensile strength
properties. FSW process was carried out using a universal milling machine (MILKO 37) on dissimilar aluminum alloy. The tool
geometry was chosen and fabricated to have a nearly flat weld of smooth interface. Throughout this project, the welding
parameter was obtained, 3 various of welding speed (44mm/min),(67mm/min) and (86mm/min), tilt angle of spin (3⁰), tool
shoulder diameter (25mm), tool pin type (Threaded Cylindrical Round Bottom) and fixed rotational speed (1280rpm). This
project has been carried out to obtain the mechanical properties of tensile strength testing at Unikl MIMET in order to achieve
the ultimate tensile strength and percentage of elongation within stress vs strain. Indication of the result has been showed in this
project report in term of graph in these 3 variables of traverse speed (mm/min) and also comparison of results displayed in the
mean graph of stress vs strain. The welding parameter of (86mm/mm) and a fixed of rotational speed was the best-suited
parameter at once has reached the objective of this project thesis.
Keywords – Friction Stir Welding (FSW), Dissimilar Aluminum Alloys, Variable Traverse Speed (mm/min), Tensile Strength
I.INTRODUCTION1
riction Stir Welding was invented and
patented by W. M Thomas of the Welding
Institute (TWI) in Cambridge, UK on December 1991.
In 1992, the Group-Sponsored Project 5651 was
established by TWI to further and enhance this
technique for the longer term in the name of
“Development of the New Friction Stir Technique for
Welding Aluminium”. (Umasankar Das and Dr. Vijay
Toppo, 2015). In FSW, a cylindrical shouldered tool
with a profiled pin is rotated and plunged into the joint
area between two pieces of sheet or plate material.
The specimens have to be securely clamped. Frictional
.
heat between the wear resistant welding tool and the
workpieces causes the latter to soften without reaching
melting point, allowing the tool to traverse along the
weld line. The plasticised material, transferred to the
trailing edge of the tool pin, is forged through intimate
contact with the tool shoulder and pin profile. Based
on Umasankar Das and Dr. Vijay Toppo, (2015), “An
overview over Friction Stir Welding”, this project was
conducted into three phases. Phase I defined as
practical welding technique of FSW within to prove
this technique is a realistic while at the same time
addressing the welding of series aluminum alloys. The
Phase II is focused on welding application advanced
which reflect to the industry such as in aerospace and
shipbuilding of aluminium alloys (6000) and (5000)
series respectively.
Friction Stir Welding (FSW) Process on
Dissimilar Aluminium Alloys at 3G Position
Mohamad Najmin B. Dzulkiflee1*
Mohamad Azrie Husainy B. Mohd Jasri2
Hazrul B. AB Dul-Hamid3
1
Marine Design Technology Department
2,3
Marine Construction and Maintenance Department
Universiti Kuala Lumpur, Malaysian Institute of Marine Engineering Technology (MIMET), Lumut, Perak
*
mindzulkiflee26@gmail.com
F

2. The composition of these two materials series is
carried out in terms of process parameter tolerances,
metallurgical characteristics, and mechanical
properties. Phase III developed pertinent data for
further industrialization of FSW.
II. WORKING PRINCIPLE OPERATION
The principal operation quoted journal from R.S
Mishra, (2005), Friction Stir Welding (FSW) concept
is to determine by the specialist of tool which is
consists of pin, shoulder and holder however, the
designer of pin and shoulder are most influence into
this principal concept as the end of the result process.
R.S Mishra also stated that the cylindrical shouldered
tool with a profiled pin is rotated and plunged into the
joint area between two pieces of sheet or plate
material as illustrated in Fig 1.1 below.
Furthermore, as a tool is rotating, there is a
frictional heat produced in between the wear
resistance tool and workpiece of material that causing
the tool to travels along the weld line without reaching
any of melting point. The tool has a two primary
function (a) the relationship heating of workpiece and
(b) movement of material to produce the joint.
Significantly, the FSW (Solid-state) can be applied to
various type of joint such as in this research paper
which is focus on butt joint configuration on 3G
position with a different welding of parameter (R.S
Mishra, 2005).
Figure 1.1: The principle of Friction Stir Welding
R.S Mishra, (2005) conclude that the principal
operational of FSW consists of three stages which are
plugging, stirring and retraction as shown in Fig 1.2.
The machine has to be set within the travel and
rotation speed of the tool into the workpiece at the
optimum of high rotational these two speed and
plugging on top of weld surface. After that, as the tool
weld and travel at the weld spot it can enable the
material piece to mix well together. This process is
called stirring stage. Lastly, the once a predetermined
penetration is successfully reached, the process stops
and the tool retracts form the workpiece.
Figure 1.2: a) Plunging, b) stirring, and c) retraction
III. WELDING PARAMETER
According to Umasankar Das and Dr. Vijay
Toppo, (2015), “An overview over Friction Stir
Welding”, stated that there are a plenty of welding
parameters need to take when using FSW as a
machining process. It’s important to clarify this
parameters if FSW is the chosen process. Choice the
material for a tool is dependent on the type of metal
material to be welded, particularly the melting
temperature of the material.
It is support by R.S Mishra, (2005), “Friction stir
welding processing”, there are two important things to
be considered relating to the welding parameter which
are tool rotation rate (v, rpm) in clockwise or counter-
clockwise direction and tool traverse speed (n,
mm/min) along the line of joint. The rotation of tool
reacts into the weld area and produce the heat
treatment around it from the front to the back of the
pin is need to be considered.
As stated by Y.N Zhang X, S.Larose and P.
Wanjara, (2012), angle of spindle or tool tilt with
respect to the workpiece surface is part that to be
include. Further, the insertion depth of pin into the
workpieces (also called target depth) is important.
When the insertion depth is too deep, the shoulder of
tool plunges into the workpiece creating excessive
flash. In this case, a significantly concave weld is

3. choose according into this project since the depth of
pin size is 4.80mm within the 5mm thickness of the
aluminum alloys plates, hence it is produced, leading
to local thinning of the welded plates.
Table 1.2: List of Parameters to be considered
Traverse speed (mm/min) was constant to make
sure the optimum welding quality of rotational speed
factor can be produce. The traverse speed will not
effected the strength of the joint. In the aspect of
welding travel speed, it controls the appearance and
the heat control where the heat produced from the
contact between the probe concave shoulder and the
work piece. The rotational speed is one of the main
parts in welding parameter. The variation of the
tensile properties of the joint welded at different weld
speed and tool rotational speed. Based on Fig 1.3, the
tensile strength resulted by rotational speed of 800rpm
was the highest between others.
Figure 1.3: Tensile strength with different rotational
speed (rpm)
Most of the study shows that the angle of tool pin
causes a serious problem in the weld defect such as
wormhole and tunnel. Based on Table 1.3, a small
increment on the tilt angle helps to increase the joint
strength until the tilt angle of 2 degrees. An optimum
tilt angle was obtained at 3 degrees, lower and higher
tilt angle cause a decrement on the joint strength.
The joint strength was increased 71.34 % by
selection of 3 degrees instead of 0 degrees. The higher
tilt angle needs a lower rotational speed in order to get
good weld strength. It can be seen that design
parameters have an influence on the strength of the
welded joints. Selection of proper FSW design
parameters result in an increase of the joint strength.
Table 1.3: FSW parameters and conditions, tool
material, and tilt angles spin
Table 1.4: FSW welding parameter selected
Rotational speed
(RPM)
1280
Traverse speed
(mm/min)
44,67,86
Pin type
threaded cylindrical
round bottom
Concave shoulder
diameter (mm)
20
Tilt angle 3°
IV. TOOL OF (FSW)
The tool has two primary functions where is to
localized heating and material flow. In the initial stage
of the tool plunge, the heating is a result primarily of
the friction between the pin and work piece. Some
additional heating is caused by deformation of the
material. The friction between the shoulder and work
No Parameters
1 Travel Speed (mm/min)
2 Rotational Speed (RPM)
3 Tool Design (mm)
 Pin Depth & Diameter
 Shoulder Diameter
 Type of materials
4 Material of weld
5 Angle of tilts

4. piece results in the biggest component of heating.
From the heating aspect, the relative size of the pin
and shoulder are important. An FSW tool consists of a
shoulder and a pin. Besides that, the tool behavior is
to ‘stir’ and ‘move’ the material. The tool rotational
speed must rotate to generate heat on the joint and
move along the traverse direction along the length of
the joint and transmitting that heat to the plates. ). The
tool will be tipped with probe or pin which typically
rotates within the range of 900 to 1500 rotations per
minute (rpm).
The tool tilt is important in FSW process because
it can cause major effects on the welding process. A
general range for tool tilt is between 2 and 4 degrees
in for the way that the tool leans into the joint. The tilt
also can effect on the tool movement across the
traverse joint line. It is because less pressure is put in
the direction of the joint line.
Umasankar Das and Dr. Vijay Toppo, (2015),
“An overview over Friction Stir Welding”, stated that
tool material characteristics can be critical for FSW.
Ideally, the tool material should meet the following
characteristics:
1. Low or affordable cost.
2. Full durability, dimensional stability and creep
resistance.
3. Good thermal fatigue strength to withstand
repeated heating and cooling cycles.
4. Good fracture toughness to withstand the damage
during plunging and dwelling.
5. Higher compressive yield strength at elevated
temperature than the expected forge forces onto
the tool.
6. Good machinability to ease manufacture of
complex features on the shoulder and probe.
7. Low coefficient of thermal expansion between the
probe and the shoulder materials to reduce the
thermal stresses.
H13 tool is chosen due to its easy machinability
material compared to other which is stated by Y.N
Zhang, X. Cao, S. Larose and P. Wanjara, (2012). R.
Rai, A. De, H. K. D. H. Bhadeshia and T. DebRoy, (2011)
stated that it can be used to operate at 600 to 1500 rpm
which is within rotation speed of this research scope.
This material is classified as hot worked tool steel
with good tensile and wears resistance properties and
also easy availability and machinability, thermal
fatigue resistance, fatigue resistance, especially for
aluminum and copper.
Figure 1.4: Tools has been completed through the
H13 process
V. SHOULDER DIAMETER & SHAPE OF (FSW)
The shoulder diameter and the rotational speed
are the most important factors. In journal Friction Stir
Welding Tools wrote by R. Rai, (2011) stated that the
tool shoulder produce heat. When the shoulder is grip
on the materials, it will be sliding and sticking which
is the main reason for heat to be generated. Therefore,
it is important to determine the diameter of the tool
since it grip on the plasticized materials which create
the material flow field.
Elangovan and Balasubramanian, (2015) studied
FSW of AA6061 with 15, 18, and 21 mm shoulder
diameter tools, each with five pin profiles at a
constant rotational speed pf 1200 rpm and a linear
velocity of 1.25 mm s-1 for welding of 6mm thick
plates. They reported that the tool with 18mm
shoulder diameter size produced defect free welds
irrespective of pin geometries. In this project, 20mm
diameter was chosen to be test. There are some types
of the shoulder’s shape. For example, convex,
concave, and flat shoulder are portrayed in Fig 1.4
with some of shoulder shape type.

5. Figure 1.4: Differences of Shoulders shape
The featureless shoulder is more effectively than
other based on the journal research which is surface
having a reasonably finish due to the rotational and
traverse speed, better surface produce, nugget zone
long grains are observed contain sub grains, sub-
boundaries and dislocations.
The tool of shoulder diameter size (20mm) is
optimum and fixed as designed in Figure 1.5 below.
Increase in the welding speed apparently lead to an
increase in the tensile strength of the specimen. In
fact, the tensile strength approached a maximum value
close to the lesser of the parent base materials then
allowing to minimize with increasing the welding
speed on the dissimilar friction stir welding specimen.
VI. PROBE/PIN SHAPE
In journal of Review of Tools for “Friction Stir
Welding and Processing” by Y. N. Zhang, X. Cao*, S.
Larose and P. Wanjara, (2012) stated that the friction
from stirring probe can change the state of the metal.
It was used to go down in between the plates or
contacting surface of the plates and blend the material
in front of the tool and then move the blended plates
behind the tool. The pin that go down into the plate or
depth deformation and the travel speed are depends on
the probe.
Fig 1.5 shows the shape of the probe/pin and
their features. It is either flat or domed shape for the
end probe shape. The favorite type of bottom probe
design is flat bottom because it is easy to manufacture.
But the flat bottom probe/pin is create high forge force
during plunging. While the other shape like domed or
round end shape can minimize the forge force and the
tool become more resist upon plunging which can be
used in long term by remove the local stress
concentration. Other than that, the velocity of the
surface at the probe edge can affect the stirring power.
So it will make the metal that had been blended flow
under the probe/pin end.
Figure 1.5: Types of Pin shape
VII. ALUMINIUM ALLOYS
According Ron Cobden and Alcan Banbury,
(2000), an aluminium (AI) is the crucial part of metal
with alloying elements content such as copper, silicon,
zinc, tin, manganese and also magnesium. Casting
alloys and wrought alloys are the branch of aluminium
alloys principal characteristics. Generally, cast alloys
has a desired forms in term through a one of three
methods (sand-casting, gravity die casting or pressure
die casting) meanwhile wrought alloys are in ingots or
billets in between hot and cold worked mechanically
into extrusions, forgings, sheet, foil, tube and wire.
Ron Cobden and Alcan Banbury also determine,
the alloying elements in their research paper
(AA5083) and (AA6061) are Aluminium -
Magnesium Alloys (EN system EN AW 5XXX e.g.
5083). The characteristics of 5XXX series is non heat-
treatable posture and the resistance to corrosion is a
good combination. This composition has its own
advantages when the Mg level is exceed, there is a
tendency of corrosion resistance to be reduced. As for
example, the pressure vessels, bulk road and rail
vehicles, ships structures, chemical plant. It can be

6. hardened by cold work, but is not heat treatable to
higher strength. It has good ductility for the strength
level, better than most other 5000 series alloys.
Fabrication of Aluminium 5083 is readily cold
formable, as it is ductile.
Aluminium - Magnesium - Silicon Alloys (EN
Systems EN AW - 6XXX 6061). This group of heat-
treatable alloys uses a combination of magnesium and
silicon (magnesium Silicide) to make it optimize a
heat-treatable. The advantages of these alloys has their
greatest strength moreover it can be ease of
formability. The combination of alloying elements
make it a good corrosion resistance and the ability to
be anodized. Because of that, it has good mechanical
properties and exhibits better weld ability. Fig 1.6
below shows the chemical composition (mass %) and
mechanical properties of AA5083 and AA6061.
Figure 1.6: Chemical composition (mass %) and
mechanical properties of (AA5083) & (AA6061)
Richard Tenagalia, (2012) mentioned that
generally, the difficulties of joining similar material is
often easier rather than joining of dissimilar material
because the composition and mechanical properties
structure. However, in a recent days, there’s a lot of
dissimilar materials can be joined successfully with
the appropriate joining process and specialized
procedures. Some of this action must be taken in order
to get a prefect and accurate when designing a
dissimilar materials joining, such as:
1. Joint design and material thicknesses
2. Differences in melting temperature
3. Thermal expansion-contraction mismatch
during joining and in service
4. Featuring and constraint effects on joining
stresses
5. Formation of brittle intermetallic compounds
during joining which may lead to brittle joints
6. Heating and cooling rate effects on the
microstructure of the joint, which may affect
the strength and precision control of heat
7. Needs for pre and post heating to minimize
stresses during welding and cooling
8. Needs for composite transition materials or
special filler materials during joining
9. Potential for galvanic corrosion problems in
service
Heat-treatable and high strength are common
used materials, such as 7075, 7475, 2024, 5083 and
6061. As a commercial alloy with corrosion resistance
and moderate to high strength, the 5083 aluminium
alloy is widely applied in sheet forming processes.
Additionally, the 6061 aluminium alloy has been
studied extensively because of its benefits such as
moderate strength, good formability and corrosion
resistance. (Jun Liu and Ming-Jen, 2010)
VIII. EXPERIMENTAL SETUP
MILKO 37 is a universal milling machine that
has been used in this study. Data specification of the
machine is suitable to conduct this experiment of
friction stir welding in 3G position. There have a
variable speed of rotation tools and traverse speed as
shown in Fig 1.7. Adjusting the speed can be made by
turning the lever on the machine to set up the speed
needed. The data of MILKO37 milling machine can
be found and take form the manual guide book and
internet research.
Fig 1.7: Universal Milling Machine MILKO37

7. At the first stage, the jig was designed as a sketch
and meets all the requirement specifications of milling
MILKO37 machine and after that, redesign into the
AutoCAD and Autodesk Inventor in order to get
actual design and 3D dimensions view. Fig 1.8 below
Figure 1.8: Design of Jig in AutoCAD
Function of jig is used to clamp and control the
location or motion of the specimen. The material to be
used for manufacturing the base jig is mild steel plate
(470mm x 400mm x 10mm) which is used as a base of
the jig uphold to withstand the jig in the positon of 3G
and also mild steel angle bar (300mm x 75mm x
5mm) cutting according the materials specifications.
On the other hand, the material of fine surface to be
used for the jig is mild steel plate with dimension of
(640 mm x 330 mm x 10 mm). Specimen will attached
on the jig before start the welding experiment. The
bold and nut are used to grip the plate specimen on top
and right side of the angle bar and also the jig on the
working table based in Fig 1.9 above
Figure 1.9: Design of Jig in AutoCAD
Total length of tool is (70.2mm), where the
length of threaded cylindrical pin round bottom
(4.80mm), shoulder length (20.2mm) and holder
(50mm), tilt angle (3˚) with the (20mm) size diameter
of concave tool. The design has been choose can give
affective and optimum result to the project experiment
base on the objective of the project experiment within
the 3G position configuration.
Figure 2.0: Design of Tool with shoulder (20mm)
Base of Jig
Fine surface
Backing
Plates
Angle Bar

8. Figure 2.1: Tool with machine holder
The specimen dimension was made to small clear
size of (270 mm x 150 mm) with 5 mm thickness in
two plates (AA6061) and (AA5083) based on
American Society for Testing and Materials (ASTM)
standard code and American Welding Society (AWS
D17.3/D17.3M:2010)
Figure 2.2: The position of Jig in 3G positon
IX. RESULTS AND DISCUSSION
This experimental was carry out with 3 variables
of the traverse speed parameter at a fix 1280 RPM
which were 44 mm/min, 67 mm/min and 86 mm/min.
From those variables, it can be observed that
sequences of the traverse speed as the variables from
the tensile testing using (INSTRON 600DX) yet to
find its strength such as Load, Stress, Tensile strength
and Elongation at these different parameters. The
testing speed was set at 1.0 mm/sec in room
temperature. The data were collected and has been
analyses to find the comparison of FSW parameters.
Results were collected and gathered by using
destructive testing of tensile testing.
Table 1.7: Surface welding with different
transverse speed (mm/min)
Result of Surface Welding
44mm/min traverse speed
 Surface welding at starting is sufficiently smooth
 No flash produce
 Good penetration
 Worm hole produce at the end of welding surface
67mm/min traverse speed
 Surface welding is smooth and become rougher at the
end of welding surface.
 Slightly flash form at the side of weld
 Good penetration
 Worm hole produce at the end surface
86mm/min traverse speed
 Surface welding is smooth and leave a little rough
marking on weld joint surface
 Flash at the side of weld.
 Good penetration
 No worm hole appear
Threaded round bottom
Shoulder
Machine
Holder
Worm Hole
Worm Hole
Flash excessive area
Flash excessive area
AA6061 AA5083

9. Figure 2.3 Mean graph Stress vs Strain of all traverse
speed (mm/min)
Graph above shows the mean tensile properties
between stress and strain of the joints of FSW
technique which can be compared for the
combinations of parameters. In all of the cases, the
joints made with the group of parameters with traverse
speed of (86 mm/min) presented highest of ultimate
tensile strength (97.4346 MPa) and longest percentage
of elongation which is (0.00325 mm/mm). It is
because the criteria of the specimens of (86 mm/min)
is meet the requirement of American Welding of
Society (AWS) specifications which are the surface
welding is smooth, no worm hole appear and also a
good penetration along the weld line.
The deformation of the specimens begin in yield
stress at the stage of plastic region and continue in the
elastic region in which stage of this parameter acts as
the material regains its original shape when the
applied force is removed. The largest stress is indicate
in the graph above and it’s slowly begin to necking
until finally the specimen will suddenly break at the
fracture stress. The traverse speed of (44 mm/min)
specify the second utmost strength of maximum load
with (80.8146 MPa) and the elongation of strain is
(0.00285 mm/mm).
The welding surface of (44 mm/min) traverse
speed is pretty smooth more than 80% and no
appearance of flash produce. However, the worm hole
is produced at the end of weld joint surface but it still
created a good penetration not as good as (86
mm/min) of traverse speed weld criteria. Traverse
speed of (67 mm/min) shows the lowest result in
tensile strength and decrease percentage of elongation.
The condition of weld joint in this parameter is
slightly flash form at the first joint and become
rougher. Although, it’s formed a good penetration but
there is minor of worm hole at the end surface that
will affect the tensile strength outcome. The most
significant differences in the properties, when the
parameters were changed in the joints made in the
milling machine, being around 17 MPa or 16%
difference.
X. CONCLUSION
The welding parameter of (86mm/mm) and a
fixed of rotational speed, (1280 rev/sec) was the best-
suited parameter at once has reached the objective in
which to determine and evaluate the best parameter
for 3G position of FSW process on dissimilar
aluminium grade of (AA5083) and (AA6061).
Although the weld surface of finishing line is leaving
a little rough at the marking joint but the tensile
strength showed it has a better and perfect strength.
Friction Stir Welding (FSW) can produce
satisfactory butt welds between (AA5083) and
(AA6061) grade dissimilar aluminium alloys with a
joint efficiency of around 60% to 90% (based on alloy
grade specifications chemical contains). The strength
of welding joining is strong based on the elongation
result. The quality of (20mm) concave shoulder size
with respective of cylindrical threaded round pin tool
bottom (4.80mm) was found to be very suit and good
because the contact condition under the shoulder can
stir and fusion effectively and efficiency. It can be
describe by sliding friction, using a friction coefficient
and interfacial pressure or sticking fraction, based on
the interfacial shear strength at an appropriate
temperature and strain rate. Moreover it can create an
impeccable of mechanical properties of solid weld
joint. The probe tool pin length should be about 85-
90% of the materials thickness in order to avoid the
wormhole occur, so that the tools pin can perfectly stir
the materials to fusion smooth together.

10. In addition, there’s had an impromptu things that
came out while this project was in undergoing which
is based on Table 1.7 each of these parameters of
welding surface has a start-stop welding technique due
to the out of milling machine failure travelling. The
modification of conventional milling machine MILKO
37 to make butt joint process using friction stir
welding technique is another innovation for those who
want to try new invention in welding technology
within the a new invention of jig design. With a low
cost of finance to invest they will observe long period
saving of labor cost and material waste during
welding process.
XI. ACKNOWLEDGEMENT
The authors would like to thank Universiti Kuala
Lumpur Malaysian Institute of Marine Engineering
Technology (MIMET) for full advance in assistance
and financial provided.
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