Abstract—Friction Stir Welding (FSW) is a relatively new joining process that has exhibited many advantages over traditional arc welding processes, including greatly reducing distortion and eliminating solidification. The present work aims to determine the feasibility to weld two pieces of aluminum pipe by friction stir welding process and study the effect on the mechanical properties of welding joints. Special welding fixture fixed on conventional milling machine has been conducted to attempt this welding and group of welding parameters. Three tool rotational speeds (500, 630, 800 rpm) with four welding speeds (0.5, 1, 2, 3 mm/sec) for each rotational speed had been used to study the effect of each parameters (tool rotation, weld speed) on mechanical and microstructure properties of welded joints. Mechanical properties of welded joints were investigated using different mechanical tests including non destructive test (visual inspection, X-ray) and destructive test (tensile test, microhardeness and microstructure). Based on the stir welding experiments conducted in this study the results show that aluminum pipe (AA 6061-T6) can be welded by (FSW) process with a maximum welding efficiency (61.7%) in terms of ultimate tensile strength, using 630 (RPM) rotational speed, 1 (mm/sec) traveling speed.

Index Terms—Friction Stir Welding, 6061-T6 Al Pipe, Feasibility, Mechanical properties

Cite: Qasim M Doos and Bashar Abdul Wahab, "Experimental Study of Friction Stir Welding of 6061-T6 Aluminum Pipe," International Journal of Mechanical Engineering and Robotics Research, Vol.1, No.3, pp. 143-156, October 2012.