Abstract—Friction Stir Welding (FSW) is a materials joining process with great potential as joint quality is exceptionally high and the process is very repeatable. These geometries are used extensively in aerospace vehicles, in nautical vessels, and in pressure vessels. In this work, friction stir welding is applied to the joining of two pipes, thin-walled, thickness variable hollow hemispheres. The aim of this work 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 drilling machine has been conducted to attempt this welding and group of welding parameters. The tool rotational speeds 485, 710, 910, 1120 and 1400 rpm with a traverse speed 4mm/min were applied. The Mechanical properties of welded joints were investigated using different mechanical tests including non destructive test (visual inspection) and destructive test (tensile test, hardness and microstructure). Based on the stir welding experiments conducted in this study the results show that aluminum pipe (6061) can be welded by (FSW) process with a maximum welding efficiency (78.7%) in terms of ultimate tensile strength, using 1400 (RPM) rotational speed, 4 (mm/min) traveling speed.

Index Terms—FSW, Al alloys, Mechanical properties, Microstructure

Cite: A M Khourshid and I Sabry, "Analysis and Design of Friction Stir Welding," International Journal of Mechanical Engineering and Robotics Research, Vol.2 No.3, pp. 233-241, July 2013.