Linear and rotational velocities effects of friction stir welding tool on AA6061-T6 aluminum alloy T-joint

Increase of strength and development of aerial structures has long been of interest to researchers. In this study, to investigate the T-joint T6-6061 aluminum alloy using friction stir welding process, laboratory samples were made, and also the software simulations were performed to find out the appropriate amounts of tools dynamic effects. Fluent commercial software has been used to better understand heat generation and distribution in the welding process. For this purpose, the T6-6061 aluminum joint with different linear and rotational tools speeds was studied. Depending on the selected parameters in the process, the strongest connection was produced in the 1600 rpm rotational speed and 68 mm/min linear velocity. The failure place of all tensile samples was located on the aluminum T appendage. Tunnel void was the major defect in the joints which disappeared with increasing heat input and simultaneous cooling rate to the joint. The maximum strength produced in these experiments is 188 MPa which is close to the strength of the aluminum base metal.