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<p>This study investigates the effect of process parameters on the formation of internal tunnel voids in friction stir welding (FSW) of 2-mm-thick AA6061-T6 butt joints. Three welding parameters, including plunge depth, spindle speed, and welding velocity were systematically varied, while the probe temperature and bending force were recorded in real time using an instrumented FSW tool. Internal defects were quantified by X-ray computed tomography (CT). The results show that a standard condition (plunge depth 1.85&#xa0;mm, spindle speed 3000&#xa0;rpm, welding speed 1500&#xa0;mm/min) produced a defect-free weld with a characteristic probe temperature of approximately 498&#xa0;°C at the weld mid-length. Departing from this condition by reducing plunge depth or spindle speed, or increasing welding speed, lowered the probe temperature and markedly increased the void volume, with shallow plunge depths causing the most severe tunnel defects. When the analysis was restricted to welds made at a constant plunge depth of 1.85&#xa0;mm, the normalized void volume decreased almost linearly with increasing probe temperature, with a high coefficient of determination (R² = 0.8985). These findings demonstrate that, within an appropriate parameter window and with adequate plunge depth, the probe-tip temperature is a useful process indicator for defining a safe welding regime to suppress internal void formation. The combined use of in-situ temperature and force monitoring with CT-based defect quantification provides a quantitative framework for process optimization in FSW of thin aluminum sheets.</p>

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Effect of welding parameters on void defect formation in friction stir welding of 6061 aluminum alloys

  • 期刊论文

  • 发表日期：

    2026年3月6日

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  • Van Hanh Bui,
  • Quang Ngoc Trinh,
  • Le Duy Han,
  • Huy Le Phan,
  • Ryoga Shiotsu,
  • Koji Murakami,
  • So Fukui,
  • Kengo Yamamoto,
  • Tetsuo Suga,
  • Yoshiaki Morisada,
  • Hidetoshi Fujii

摘要

This study investigates the effect of process parameters on the formation of internal tunnel voids in friction stir welding (FSW) of 2-mm-thick AA6061-T6 butt joints. Three welding parameters, including plunge depth, spindle speed, and welding velocity were systematically varied, while the probe temperature and bending force were recorded in real time using an instrumented FSW tool. Internal defects were quantified by X-ray computed tomography (CT). The results show that a standard condition (plunge depth 1.85 mm, spindle speed 3000 rpm, welding speed 1500 mm/min) produced a defect-free weld with a characteristic probe temperature of approximately 498 °C at the weld mid-length. Departing from this condition by reducing plunge depth or spindle speed, or increasing welding speed, lowered the probe temperature and markedly increased the void volume, with shallow plunge depths causing the most severe tunnel defects. When the analysis was restricted to welds made at a constant plunge depth of 1.85 mm, the normalized void volume decreased almost linearly with increasing probe temperature, with a high coefficient of determination (R² = 0.8985). These findings demonstrate that, within an appropriate parameter window and with adequate plunge depth, the probe-tip temperature is a useful process indicator for defining a safe welding regime to suppress internal void formation. The combined use of in-situ temperature and force monitoring with CT-based defect quantification provides a quantitative framework for process optimization in FSW of thin aluminum sheets.