International Research Journal of Innovations in Engineering and Technology - IRJIET International Open Access, Monthly, Peer Reviewed, Reputed Journal ISSN (online): 2581-3048

Impact Factor (2025): 6.9

DOI Prefix: 10.47001/IRJIET

The Effect of Friction Stir Welding Process Parameters on the Butt Joint Strength of 5083 and 6061 Aluminum Alloys

Muhammad TaufikMechanical Engineering Department, Diponegoro University, Semarang, IndonesiaGunawan Dwi HaryadiMechanical Engineering Department, Diponegoro University, Semarang, IndonesiaIsmoyo HaryantoMechanical Engineering Department, Diponegoro University, Semarang, IndonesiaRusnaldyMechanical Engineering Department, Diponegoro University, Semarang, IndonesiaSri NugrohoMechanical Engineering Department, Diponegoro University, Semarang, IndonesiaOjo KurdiMechanical Engineering Department, Diponegoro University, Semarang, Indonesia

Vol 8 No 12 (2024): Volume 8, Issue 12, December 2024 | Pages: 110-116

International Research Journal of Innovations in Engineering and Technology

OPEN ACCESS | Research Article | Published Date: 23-12-2024

doi Logo doi.org/10.47001/IRJIET/2024.812016

pdf iconFull Text PDF
Abstract

This journal discusses the process parameters of friction stir welding (FSW) for joining aluminum 5083 and aluminum 6061. The welding process was conducted to identify the optimal parameters for achieving high-quality joints. Based on the study's findings, the welding parameters of a tool rotational speed of 1400 rpm, a travel speed of 30 mm/s, and a tool tilt angle of 1° were identified as the best. Various tests, properties mechanical and microstructural evaluations, were conducted to assess the quality of the joints. The results indicated that the best tensile strength achieved was 180.45 MPa, corresponding to an efficiency of 78%, while the hardness value reached 65 Hv. Furthermore, the welding process under these parameters facilitated the refinement of grain size in the Weld Nugget (WN) zone, enhancing the bonding area between the two materials. This is attributed to the ability of FSW to break coarse grains into finer grains, leading to improved microstructural uniformity and consistent grain size due to the optimized process parameters.

Keywords

Friction Stir Welding, Dissimilar Welding, Aluminum 5083-6061, Grain Size, Process Parameters


Citation of this Article

Muhammad Taufik, Gunawan Dwi Haryadi, Ismoyo Haryanto, Rusnaldy, Sri Nugroho, Ojo Kurdi. (2024). The Effect of Friction Stir Welding Process Parameters on the Butt Joint Strength of 5083 and 6061 Aluminum Alloys. International Research Journal of Innovations in Engineering and Technology - IRJIET, 8(12), 110-116. Article DOI https://doi.org/10.47001/IRJIET/2024.812016

Licence Copyright (c) 2026 International Research Journal of Innovations in Engineering and Technology creative common licence This work is licensed under Creative common Attribution Non Commercial 4.0 Internation Licence
References
  1. D. Devaiah, D. K. Kishore, and D. P. Laxminarayana, “Effect of Material Location and Tool Rotational Speed on the Mechanical Properties of Dissimilar Friction Stir Welded Aluminum Alloys (5083-H321to 6061-T6),” Bonfring Int. J. Ind. Eng. Manag. Sci., vol. 6, no. 4, pp. 186–190, 2016, doi: 10.9756/bijiems.8311.
  2. Z. B. He, Y. Y. Peng, Z. M. Yin, and X. F. Lei, “Comparison of FSW and TIG welded joints in Al-Mg-Mn-Sc-Zr alloy plates,” Trans. Nonferrous Met. Soc. China (English Ed., vol. 21, no. 8, pp. 1685–1691, 2011, doi: 10.1016/S1003-6326(11)60915-1.
  3. S. Pars, G. A. S. Field, and O. Facilities, Welding and, vol. 3. 2009.
  4. S. Rajakumar, C. Muralidharan, and V. Balasubramanian, “Influence of friction stir welding process and tool parameters on strength properties of AA7075-T6 aluminium alloy joints,” Mater. Des., vol. 32, no. 2, pp. 535–549, 2011, doi: 10.1016/j.matdes.2010.08.025.
  5. W. Zhang and J. Xu, “Advanced lightweight materials for Automobiles: A review,” Mater. Des., vol. 221, 2022, doi: 10.1016/j.matdes.2022.110994.
  6. Nishant, S. K. Jha, and P. Prakash, “Effect of tool rotation speed on mechanical properties of underwater friction stir welding of 6061-T6 and 5083-H12 aluminium alloys,” Mater. Today Proc., vol. 91, pp. 138–142, 2023, doi: 10.1016/j.matpr.2023.05.727.
  7. G. Di Bella, T. Alderucci, F. Favaloro, and C. Borsellino, “Effect of tool tilt angle on mechanical resistance of AA6082/AA5083 friction stir welded joints for marine applications,” Procedia CIRP, vol. 118, pp. 879–884, 2023, doi: 10.1016/j.procir.2023.06.151.
  8. S. Balamurugan, K. Jayakumar, B. Anbarasan, and M. Rajesh, “Effect of tool pin shapes on microstructure and mechanical behaviour of friction stir welding of dissimilar aluminium alloys,” Mater. Today Proc., vol. 72, pp. 2181–2185, 2023, doi: 10.1016/j.matpr.2022.08.459.
  9. D. Devaiah, K. Kishore, and P. Laxminarayana, “Optimal FSW process parameters for dissimilar aluminium alloys (AA5083 and AA6061) Using Taguchi Technique,” Mater. Today Proc., vol. 5, no. 2, pp. 4607–4614, 2018, doi: 10.1016/j.matpr.2017.12.031.
  10. W. M. Thomas, “Friction Stir Welding and Related Process Characteristics,” Ina. ’98, 7 th Int. Conf. Joints Alum. Abington, Cambridge, UK, no. March, pp. 15–17, 1998, [Online]. Available: https://www.twi-global.com/technical-knowledge/published-papers/friction-stir-welding-and-related-friction-process-characteristics-april-1998#:~:text=In friction joining and forming,friction welding have been reported.
  11. Y. H. Zhao, S. B. Lin, F. X. Qu, and L. Wu, “Influence of pin geometry on material flow in friction stir welding process,” Mater. Sci. Technol., vol. 22, no. 1, pp. 45–50, 2006, doi: 10.1179/174328406X78424.
  12. B. M., “Effect of Microstructure and Mechanical Properties of Friction Stir Welded Dissimilar Aa5083-Aa6061 Aluminium Alloy Joints,” Int. J. Res. Eng. Technol., vol. 05, no. 11, pp. 58–62, 2016, doi: 10.15623/ijret.2016.0511011.
  13. K. K. Kumar, A. Kumar, and K. Nagu, “Mechanical and Corrosion Behaviour of Friction Stir Welded 5083–6061 Aluminium Alloy Joints: Effect of Base Material Position,” Trans. Indian Inst. Met., vol. 76, no. 7, pp. 19.

Copyright @ 2026 IRJIET. All Right Reserved.

Licensed underCreative Commons Attribution 4.0 International License.