Effect of rotary friction welding on mechanical properties of 6060 Al alloy

Abstract

6xxx series of aluminum alloys are prone to cracking when fusion welded without a proper filler metal. Alternatively, these alloys can be welded by rotary friction welding, a solid-state welding process, without using another material. However, the use of the correct parameters for the rotary friction welding process is a key to get sound welds. In this study, 6060 aluminum alloy was rotary friction welded with various rotation speeds, and the effects of the rotation speeds on the mechanical properties of the welds were studied. The samples were observed under scanning electron microscope, were analyzed using elemental mapping with energy dispersive X-Ray spectroscopy, and tested with micro-hardness and tensile tests. Among the studied samples, the sample welded with the rotation speed of 1700 rpm was found to be much better than the others in terms of the mechanical strength. In the observations made under the microscope, unlike the fusion welding, no cracking or other welding defects or macro segregation was noticed in the sample welded with the speed of 1700 rpm.