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<p>Aluminium 6061-T6 alloy is broadly used in industries owing to its reduced weight, superior strength, and improved corrosion properties. In the present research, a relatively new approach called ‘micro-friction stir additive manufacturing (µFSAM)’, is proposed and used to develop a multi-layered aluminium structure by joining ultra-thin sheets of aluminium 6061-T6 alloy. The process is carried out using varying tool spinning speeds ranging from 1500 to 2500&#xa0;rpm, with a constant tool traveling speed of 150&#xa0;mm/min. To validate the feasibility of the proposed µFSAM process, FESEM analysis, tensile testing and hardness measurements are conducted on the joint region of the multi-layered structure. The laminated structure exhibits a higher tensile strength of 362.61&#xa0;MPa at 2500&#xa0;rpm (higher than base material’s strength, 314.19&#xa0;MPa). The maximum microhardness is reached up to 110.8 HV at a spinning speed of 2500&#xa0;rpm. Throughout the process, no tearing, waviness of thin sheets, and clamping errors are observed, which are very common in friction stir joining of thin sheets. However, defects, such as irregular shoulder marks, flash, voids etc., are found in the weld region. Additionally, tunnel defect and bonding ligament defect are observed in the laminated structure fabricated at a spinning speed of 1500&#xa0;rpm, during FESEM analysis. Buckling distortion is also identified in the final fabricated multi-layered structure.</p>

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Fabrication of a multi-layered laminated structure of aluminium alloy using micro-friction stir additive manufacturing (µFSAM)

  • 期刊论文

  • 发表日期：

    2025年7月15日

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  • Meghnath Sen,
  • Asit Baran Puri

摘要

Aluminium 6061-T6 alloy is broadly used in industries owing to its reduced weight, superior strength, and improved corrosion properties. In the present research, a relatively new approach called ‘micro-friction stir additive manufacturing (µFSAM)’, is proposed and used to develop a multi-layered aluminium structure by joining ultra-thin sheets of aluminium 6061-T6 alloy. The process is carried out using varying tool spinning speeds ranging from 1500 to 2500 rpm, with a constant tool traveling speed of 150 mm/min. To validate the feasibility of the proposed µFSAM process, FESEM analysis, tensile testing and hardness measurements are conducted on the joint region of the multi-layered structure. The laminated structure exhibits a higher tensile strength of 362.61 MPa at 2500 rpm (higher than base material’s strength, 314.19 MPa). The maximum microhardness is reached up to 110.8 HV at a spinning speed of 2500 rpm. Throughout the process, no tearing, waviness of thin sheets, and clamping errors are observed, which are very common in friction stir joining of thin sheets. However, defects, such as irregular shoulder marks, flash, voids etc., are found in the weld region. Additionally, tunnel defect and bonding ligament defect are observed in the laminated structure fabricated at a spinning speed of 1500 rpm, during FESEM analysis. Buckling distortion is also identified in the final fabricated multi-layered structure.