IJIFR RESEARCH PAPER

1. .
5066This work is published under Attribution-NonCommercial-ShareAlike 4.0 International License
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InternationalJournalofInformative&FuturisticResearch ISSN: 2347-1697
Volume 4 Issue 2 October 2016www.ijifr.com
Abstract
The present work is the analysis of the influence shown on the process
parameters like (tool speed, feed rate and shoulder diameter) on the
metallurgical and mechanical properties of the joints fabricated by Friction
Stir Welding. Now-a -days, in many industrial applications the steels are
replaced by non-ferrous alloys, in most cases by aluminum alloy. The
aluminum 6061 alloy is most commonly used in aerospace and automobile
industries. Friction Stir Welding (FSW) is considerably new joining process
that has exhibited many benefits over traditional arc welding process
including greatly reducing distortion and eliminating solidification. The
FSW joints have higher tensile strength to weight ratio and finer micro
structure. The samples were taken under the tool rotational speed of 1950,
3080 and 4600 rpm. The present study is done to think about the impact of
input parameters on the tensile strength. The tensile quality is mostly
influenced by tool speed. The parameters taken in this examination are tool
rotational speed, feed rate and shoulder diameter. The greatest tensile
strength is obtained at Tool Speed- 3080 rpm, Feed Rate- 20mm/min and
Shoulder Diameter across 20mm.
I. INTRODUCTION
Welding is system in which we join two or more homogenous or distinctive materials with
exertion of warmth and with or without use of weight. For the welding process, the most
ANALYZE THE MECHANICAL PROPERTIES
OF ALUMINUM 6061 ALLOY USING
FRICTION STIR WELDING
Paper ID IJIFR/V4/ E2/ 007 Page No. 5066-5071 Subject Area
Mechanical
Engineering
Keywords Friction Stir Welding (FSW), Aluminium Alloy 6061, Tool Rotational
1 Kapil Singh
Associate Professor
Department of Mechanical Engineering
ARNI University, Himachal Pradesh(India)
2 Sushil Kumar
M.Tech. Student
Department of Mechanical Engineering
ARNI University, Himachal Pradesh(India)

2. 5067
ISSN: 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 4, Issue -2, October 2016
Continuous 38th Edition, Page No: 5066-5071
Kapil Singh, Sushil Kumar :: Analyze The Mechanical Properties
Of Aluminum 6061 Alloy Using Friction Stir Welding
essential base is heat. There are two sorts of There are two sorts of welding i.e. conventional
welding and stir welding. Here we talk about the Friction Stir Welding (FSW). The concept
of FSW is simple in which A non-consumable rotating tool with a specially designed pin
and shoulder is inserted into the abutting edges of sheets or plates to be joined till the
shoulder contact the top surface of work piece and traversed along the line of joint to
produce the weld(Fig1). The tool serves primary functions:
a) heating of work piece;
b) deform the material ;
c) movement of deform material to produce the joint.
Aluminium is one of the most common alloys which is widely used in several application
over the automotive and aircraft industries because of their light weight properties, better
corrosion resistant and high strength to weight ratio.
Figure 1: Friction Stir Welding
FSW have the advantages over conventional welding are:
 Strong mechanical properties
 Fine grain structure, revising power, decrease lingering hassle, pliability, and
imperviousness to erosion.
 Dissimilar material can be joined.
 Guarantee 100% weld quality.
II. LITERATURE SURVEY
 Jaimin B. Patel etal.(2014), This paper introduces the demonstration of FSW devices
by substitution of hardware pin profile alongside recreation of crest temperature
instigated in plate material and stream hassles produced in the same for friction welding
of AA6061. Results are introduced for different temperatures of aluminum compound
plate and in addition stream hassles are produced in and around the instrument pin
during the welding procedure.

3. 5068
ISSN: 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 4, Issue -2, October 2016
Continuous 38th Edition, Page No: 5066-5071
Kapil Singh, Sushil Kumar :: Analyze The Mechanical Properties
Of Aluminum 6061 Alloy Using Friction Stir Welding
 A M Khourshidetal.(2013), In this research work, friction welding is connected with
the combination of two channels, meager walled thickness variably empty glass of the
gloves. The main focus of this work is studying the impact on the mechanical properties
of the welding joints.
 B.Kiran Kumar etal.(2016), This research work is about the study of mechanical
properties and micro-structure on FSW aluminum alloy. By this study we came to know
that the pin diameter and shoulder diameter are increased with the increase in thickness
of the plates or specimen undergoing the process of FSW.
III. EXPERIMENTAL PROCEDURE
In the welding process, we require a pivoting device with a shoulder and a stick that
produces heat and encourages the stream of the diminished strong compound behind the
apparatus where the welded joint structures.The Taguchi Method will be utilized to discover
the three blend welding parameters. In this work three parameters will be taken and L9
orthogonal cluster will be chosen to advance parameters for quality of the welded joint.We
take the different parameter to achieve the greatest tensile strength. The parameters are tool
speed, feed rate and shoulder diameter. Table 1 shows the process parameters:
Table 1: Process Parameters
Level Tool Speed(rpm) Feed Rate(mm/min) Shoulder Dia. (mm)
1 1950 20 17
2 3080 25 19
3 4600 30 21
Tensile Strength calculation:
Maximum St�ength =
Maximum Load KN
Maximum A�ea ��2
For conversion of kgf into N/mm2
:1 kgf = 9.8 N/mm2
Elongation calculation:
Elongation =
Change in Length ∗
Holding Length
IV. RESULTS AND DISCUSSION
We performed nine experiments in the first run and universal testing machine is used to
calculate the tensile strength. The calculated tensile strength is shown in the table-2.The
tensile strength is calculated for the different parameters such as tool rotation speed, feed
rate and shoulder diameter.
Table 2: Tensile strength Trial 1 of the Specimens for Single Sided Joint
Speed(r.p.m)
Sample
No.
Feed
(mm/min.)
Shoulder
Diameter(mm)
Area
(mm2
)
Load
(KN)
Tensile strength
Trial1 (KN/mm2
)
1950 S1 20 16 150 9 0.06

4. 5069
ISSN: 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 4, Issue -2, October 2016
Continuous 38th Edition, Page No: 5066-5071
Kapil Singh, Sushil Kumar :: Analyze The Mechanical Properties
Of Aluminum 6061 Alloy Using Friction Stir Welding
S2 25 18 150 11.25 0.074
S3 30 20 150 18.5 0.124
3080
S4 20 18 150 20 0.133
S5 25 20 150 23.9 0.17
S6 30 16 150 17.7 0.118
4600
S7 20 20 150 17.20 0.116
S8 25 16 150 7.6 0.054
S9 30 18 150 8 0.048
Now we calculate the elongation for each nine specimen shown above at different
parameters such as feed rate, transverse speed and shoulder diameters is shown in the table:
3.
Table 3: Change in Length& Elongation
Figure 2: Effect of Welding Parameters on Tensile Strength for S/n ratio
Speed
(r.p.m)
Sample
No.
Holding length
(mm)
Change in length
(mm)
Elongation
(%age)
1950
S1 50 5.5 12
S2 50 7 15
S3 50 8 17
3080
S4 50 6.5 14
S5 50 7.5 16
S6 50 5 11
4600
S7 50 3.5 8
S8 50 3.5 6
S9 50 3 7
460030801950
-18.0
-19.5
-21.0
-22.5
-24.0
302520
201816
-18.0
-19.5
-21.0
-22.5
-24.0
Tool Speed
MeanofSNratios
Transverse Speed
Shoulder Diameter
Main Effects Plot for SN ratios
Data Means
Signal-to-noise: Larger is better

5. 5070
ISSN: 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 4, Issue -2, October 2016
Continuous 38th Edition, Page No: 5066-5071
Kapil Singh, Sushil Kumar :: Analyze The Mechanical Properties
Of Aluminum 6061 Alloy Using Friction Stir Welding
After using all the observation as given in table 2 and table 3 means and S/N ratio are
calculated and the analysis is shown by the various graph is drawn by Minitab 15 software.
The S/N ratio for Tensile Strength is calculated on Minitab 15 Software using Taguchi
Method. A greater S/N value corresponds to a better performance.
Figure 3: Effect of Welding Parameters on Tensile Strength for Means
V. DISCUSSION
Taguchi method stresses the importance of studying the response variation using the signal–
to–noise (S/N) ratio, resulting in minimization of quality characteristic variation due to
uncontrollable parameter. The Tensile strength was considered as the quality characteristic
with the concept of "the larger-the-better".
The S/N ratio for the larger-the-better is:
S/N = -10� � { ∑
�
}
Finally we got the optimum value of parameters of welding process for maximum tensile
strength which is given in Table 4.
Table 4: Optimum Value of Parameter According to S/N Ratio
Tool Speed (rpm)
Feed Rate
(mm/min)
Shoulder Diameter
(mm)
Tensile strength
(KN/mm2
)
3080 20 20 0.164
VI. CONCLUSION
For better welding issues, so many different traditional strategies had been utilized in this
way, yet they are not vigorous and have many limitations. To solve the above issues,
Taguchi system is utilized as a part of this research. The Tensile quality is mostly influenced
by Tool speed and next to it shoulder distance across & feed rate likewise influence to some

6. 5071
ISSN: 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 4, Issue -2, October 2016
Continuous 38th Edition, Page No: 5066-5071
Kapil Singh, Sushil Kumar :: Analyze The Mechanical Properties
Of Aluminum 6061 Alloy Using Friction Stir Welding
degree. The Parameters considered in the examinations are upgraded to accomplish greatest
Tensile Strength. The best setting of information procedure parameters for greatest tensile
Strength is Tool speed-3080 rpm, feedrate-20 mm/min, and Shoulder diameter across 20
mm.
VII. REFERENCES
[1] A. Arora(2011) "Toward ideal erosion blend welding instrument shoulder diameter"
Materials and Design,Vol. 64, pages: 9–13.
[2] A.Govind Reddy (2012) "Process Parameter Optimization for Friction Stir Welding of
disparate Aluminum Alloys" International Journal of Engineering Research & Technology
vol.2, ISSN: 2278-0181
[3] A.Heidarzadeh and H. Khodaverdizadeh (2012)"Tensile conduct of friction blend welded
AA 6061-T4 aluminum composite joints" Materials Science and Engineering vol. 37 page:
164– 173
[4] Ajay Kumar Revuri(2012)" Computational Analysis Of Friction Stir Welding Tools With
Various Threaded Pin Profiles" International Journal of Engineering Research &
Technology vol.2, ISSN: 2278-0181
[5] A M Khourshid (2013) "investigation and outline of grinding stir welding" International
diary of mechanical designing and automated exploration India vol. 2 page: 1820– 1829
[6] D.M. Rodrigues and A. Loureiro (2012) "Impact of friction blend welding parameters on the
microstructural and mechanical properties of AA 6016" Materials Science and Engineering
vol. 30 page: 1913– 1923.
[7] Dongun Kim (2010) "friction mix welding", mix. European Journal of Mechanics A/Solids,
Vol. 29, pages: 207–215
[8] G. Çam(2008) "Mechanical properties of contact stir butt-welded Al-5086 H32 plate"
Journal of Achievements in Materials and Manufacturing Engineering vol. 30 page: 135–
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[9] Gopi Chand (2013) "Utilization of Taguchi Technique for Friction Stir Welding of
Aluminum Alloy AA6061" International Journal of Engineering Research & Technology
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[10] H.J. Liu (2009) "Malleable properties and crack areas of friction blend welded joints of
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[11] Indira Rani M and Marpu R.N (2011) "An investigation of procedure parameters of friction
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To Cite This Article
Singh,K., Kumar,S.(2016): “Analyze The Mechanical Properties Of Aluminum 6061
Alloy Using Friction Stir Welding” International Journal of Informative & Futuristic
Research (ISSN: 2347-1697), Vol. 4 No. (2), October 2016, pp. 5066-5071, PaperID:
IJIFR/V4/E2/007.