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<p>This research work demonstrates that the improvements in weld quality depend on different process parameter effects on the tensile properties, recrystallization of the microstructure, and fatigue fracture properties of friction stir welded (FSW-ed) AA6061-T6. The optimized parameter combination of a shoulder diameter of 21&#xa0;mm, plunge depth at 0.06&#xa0;mm, and tool tilt angle of 2° with a square pin tool, gave the highest tensile strength of 302 ± 2&#xa0;MPa with joint efficiency around 97% compared to the base metal. The same optimized parameter combination yielded the maximum hardness at the nugget zone (NZ), the highest number of fatigue cycles, and inhibited the propagation of fatigue cracks due to the defect-free joint. The critical grain recrystallization occurred at the (NZ) due to the effects of an optimized square pin tool profile, tool shoulder diameter, and plunge depth combination and led to the finest grain and improved mechanical properties. The square pin tool profile gives a better-quality weld bead than its counterparts due to the pin edge pulsating effects, which lead to the best grain recrystallization. The fractography of tensile-tested fractured surfaces is different from fatigue-fractured surfaces.</p>

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Tool Pin Profile and Process Parameter Effects on Strength–Microstructure–Fatigue Fracture of FSW AA6061-T6

  • 期刊论文

  • 发表日期：

    2025年12月29日

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  • Jayashree Das,
  • P. Sreedharan Robi,
  • Prakash Kumar Sahu

摘要

This research work demonstrates that the improvements in weld quality depend on different process parameter effects on the tensile properties, recrystallization of the microstructure, and fatigue fracture properties of friction stir welded (FSW-ed) AA6061-T6. The optimized parameter combination of a shoulder diameter of 21 mm, plunge depth at 0.06 mm, and tool tilt angle of 2° with a square pin tool, gave the highest tensile strength of 302 ± 2 MPa with joint efficiency around 97% compared to the base metal. The same optimized parameter combination yielded the maximum hardness at the nugget zone (NZ), the highest number of fatigue cycles, and inhibited the propagation of fatigue cracks due to the defect-free joint. The critical grain recrystallization occurred at the (NZ) due to the effects of an optimized square pin tool profile, tool shoulder diameter, and plunge depth combination and led to the finest grain and improved mechanical properties. The square pin tool profile gives a better-quality weld bead than its counterparts due to the pin edge pulsating effects, which lead to the best grain recrystallization. The fractography of tensile-tested fractured surfaces is different from fatigue-fractured surfaces.