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Microstructure and mechanical properties of

friction stir welded 6082-T6 aluminium alloy
Article in Australian Journal of Mechanical Engineering January 2013
DOI: 10.7158/M12-100.2013.11.2

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131

Microstructure and mechanical properties of

friction stir welded 6082-T6 aluminium alloy*
S Gopi and K Manonmani
Government College of Technology, Coimbatore, Tamilnadu, India

ABSTRACT: Aluminium alloy 6082-T6 is vital in the fabrication of light weight structures
requiring high strength-to-weight ratio and good corrosion resistance. In this work, investigation
is carried out at three different heat energy inputs termed as hot weld (HW), cold weld (CW) and
weld at optimum condition (WOC). Heat energy in friction stir welding depends on spindle speed
and weld speed. The characteristic study of tensile strength, micro-hardness and metallographic
structure at different weld conditions were carried out. Higher heat input, ie. HW, shows fine and
harmonised grains, but softening occurred across the weld. Lower heat input, ie. CW, shows better
mechanical properties compared with HW, but prone to brittle fracture. The WOC compromises
the CW as well as HW and provides better results.
KEYWORDS: Friction stir welding; aluminium alloy 6082-T6; heat energy; mechanical
property; microstructure.
REFERENCE: Gopi, S. & Manonmani, K. 2013, Microstructure and mechanical
properties of friction stir welded 6082-T6 aluminium alloy, Australian Journal of Mechanical
Engineering, Vol. 11, No. 2, pp. 131-138, http://dx.doi.org/10.7158/M12-100.2013.11.2.

INTRODUCTION

Friction stir welding (FSW) is a solid state joining

process (Thomas et al, 1991) carried out with a nonconsumable rotating tool, which consists of a pin and
tool shoulder. This applies severe plastic deformation
and frictional heating into the base material. The
softened material is extruded underneath and around
the tool. As the tool shoulder forges and travels along
the welding line, it subsequently meets to form a
strong metallurgical joint. This welding process is
well suited for joining aluminium alloys, especially
the high strength alloys, which are considered
unweldable by conventional fusion welding
techniques, because it avoids the dentric structure
formed in the fusion zone which can seriously reduce
the mechanical properties of the joint (Su et al, 2003;
Cavaliere et al, 2005).
FSW can locally eliminate casting defects and refine
microstructures; thereby improving strength and
*

Paper M12-100 submitted 4/11/12; accepted for publication

after review and revision 11/03/13.

Corresponding author S Gopi can be contacted at

gooobi@gmail.com.

Institution of Engineers Australia, 2013

ductility, increasing resistance to corrosion and

fatigue, enhancing formability and improving
other properties. This process can also produce fine
grained microstructures in stir the zone, to impart
super plasticity. In general, the microstructure of a
friction stir weld is classified into three major regions,
namely weld nugget (WN), thermo-mechanically
affected zone (TMAZ) and heat affected zone (HAZ).
The WN is characterised by severely deformed and
dynamically recrystallised region. Microstructure
changes and their resulting effect on mechanical
properties are significant in FSW heat-treatable
aluminium alloys. It is mainly due to the growth,
dissolution, and re-precipitation of the strengthening
precipitates after FSW (Singh et al, 2011; Sakthivel et al,
2009; Moreira et al, 2009). The objective of the present
work is to investigate the effect of different heat energy
inputs on microstructure and mechanical properties
of friction stir welded 6082-T6 aluminium alloy joints.
2

EXPERIMENTAL PROCEDURE

The 6xxx-group is high strength Al-Mg-Si alloys

that contain manganese to increase ductility and
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Microstructure and mechanical properties of friction stir welded ... Gopi & Manonmani

toughness. Aluminium alloy 6082 has the highest

strength among the 6000 series alloys with excellent
corrosion resistance property. Alloy 6082 is known
as a structural alloy. Chemical composition and
mechanical properties of AA6082-T6 are provided in
tables 1 and 2, respectively. Aluminium alloy 6082-T6
was cut to dimension 200766 mm. Square butt
joint configuration was prepared to fabricate FSW
joints with the non-consumable HCHCr tool (Gopi
& Manonmani, 2012a).
Non-consumable tools made of high carbon high
chromium steel were used to fabricate the joint
because of its high strength, high hot hardness,
easy to process, easy availability and low cost
(Vijay & Murugan, 2010). Friction stir weld tool has
two parts, namely shoulder and pin. In this study
shoulder diameter of 18 mm and pin diameter of
6mm were taken to fabricate the joint (Elangovan &
Balasubramanian, 2008a; 2008b). The optimum pin
profile is taken from the previous experimental work
describing the optimisation (Gopi & Manonmani,
2012b). Hexagonal pin profile has been taken for the
weld and it has shown in figure 1. Pin profiles were
cut by spark erosion with WEDM machine and others
including inward and outward taper of the shoulders
were obtained in CNC turning centre. The tools were
oil hardened to bring 60-62 HRC and were tempered
to bring back its original strength.
The experiments were carried out on conventional
HMT FN2V vertical milling machine (Milton &
Mynors, 2006) with capacity of 7.5 HP and 1800
rpm. After several trials, such a way that the joint
should be free from visible defects, the range of tool
rotational speed and welding speed were taken from
700 to 1500 rpm and 0.8 to 4 mm/s, respectively. The
spindle speed and weld speed plays a vital role in
heat generation in FSW (Choa & Qi, 1998).

is maintained for excellent stirring condtions. The

existing experimental results showed: the spindle
speed of 1100 rpm, 3.2 mm/s weld speed, and
hexagonal pin profile reveals good results on tensile
strength for 6 mm thickness plate (Gopi & Manonmani,
2012b). From the above mentioned working zone, the
weld conditions are termed as follows:
hot weld (HW) higher heat energy, 1500 rpm
spindle speed, 0.8 mm/s weld speed
cold weld (CW) lower heat energy, 700 rpm
spindle speed, 4.0 mm/s weld speed
weld at optimum condition (WOC) optimum
heat energy, 1100 rpm spindle speed, 3.2 mm/s
weld speed.
Welded plates were cut at mid welded portion and
specimens of size 40106 mm were obtained for
metallographic study. The samples were prepared
as per standard metallographic procedure from
the welded plates and macro etched using Kellers
solution (Beraha & Shpigler, 1977). The images of the
macrograph of the etched specimen were captured
using an optical scanner. The metallographic study
was carried along various zones of parent metal,
HAZ, TMAZ and WN across the cross sections
of friction stir welded specimens using scanning
electron microscope (SEM).
3

RESULTS AND DISCUSSION

3.1

Tensile strength

The material was welded according to the above

mentioned specifications of different welding

Q = f (spindle speed, weld speed)

where Q is proportional to spindle speed and
inversely proportional to weld speed.
Combination of higher spindle speed with lower weld
speed generates more amount of heat. The inverse
combination generates a low amount of heat. The
generated heat should be sufficient to plasticise the
material and overcome the sticking friction, however,
it should not be too high so tool-material contact

Figure 1:

Friction stir weld tool.

Chemical composition of the 6082 alloy (wt%).

Table 1:

Si

Fe

Cu

Mn

Mg

Cr

Zn

Ti

0.7-1.3

0.50

0.10

0.4-1.0

0.6-1.2

0.25

0.20

0.10

Table 2:

Mechanical properties of the 6082 alloy.

Yield strength
(MPa)

Ultimate
strength (MPa)

Elongation (%)

Hardness
(HRB)

Density
(g/cm3)

Melting point
(C)

143

300

11

117

2.70

555

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Microstructure and mechanical properties of friction stir welded ... Gopi & Manonmani

conditions such as HW, CW and WOC. The welded

specimens were fabricated as per ASTM-E8 standards
to evaluate the tensile strength of the joints (ASTM,
2006). Tensile strength of the FSW joints was
evaluated by conducting tests in a TUE-CN-1000
universal testing machine. For each welded plate,
three specimens were prepared and tested. Figure 2
shows the tensile specimen after fracture. The fracture
has occurred mostly in the HAZ on the retreating side
of the weldment. Table 3 shows the tensile strength
of welded joints that has been fabricated at different
weld conditions of HW, CW and WOC.

3.2

Specimen after tensile test.

Table 3:

Experimental value of tensile strength.

Micro-hardness

Micro-hardness of the welds was measured at

test load of 5 N for 10 seconds as per ASTM E-384
standards (ASTM, 2006). The indentations were made
at midsection of the thickness of the plates across the
joint. Reduction in hardness in the weld zone is usual
in the friction stir welds of artificial aged aluminium
6000 series up to 50% depending upon the energy
input and temperature condition of the alloy. Figure
3 represents the results of micro-hardness of the
welded joints prepared at various heat inputs termed
as HW, CW and WOC. The hardness of HAZ and
WN are lower than that of base metal in all the joints.
The difference between HAZ and WN is attributable
to the grain refinement in WN, caused by intensive
stirring and produced very fine harmonised grains.

At low spindle speeds, frictional heat generation is

less which results in the poor plastic flow of material.
Therefore lower tensile strength was observed. At
higher spindle speeds, frictional heat generation
is high which enhances the plastic flow of material
thus loses the tool material contact. So the poor
stirring was obtained. At the highest welding speed
of 4.0mm/s and lowest welding speed of 0.8 mm/s
lower tensile strengths were observed. This is due to
the increased frictional heat and insufficient frictional
heat respectively (Lee, 2005; Gopi & Manonmani,
2012c). The tensile strength of CW was higher
than the HW. This is because of material softening
obtained at higher temperatures. The WOC has been
compromised at both extreme weld conditions of
CW and HW.

Figure 2:

133

Harris & Norman (2003) suggested that the variation

of the micro-hardness values in the welded area and
parent material is due to the difference between
the microstructures of the base alloy and weld
zone. As compared to base material, considerable
softening occurs throughout the weld zone due to
the elimination of strain-hardening effect by dynamic
recrystallisation. Hence, the hardness decreases in
TMAZ towards the WN as compared to the parent
metal. The CW shows the abrupt variations. The
insufficient heat energy is the main cause, which

Experiment nature

Spindle speed
(rpm)

Welding speed
(mm/s)

Tensile strength
(MPa)

Joint efficiency
(%)

HW

1500

0.8

110.17

76.9

WOC

1100

3.2

123.18

86.1

CW

700

4.0

112.36

78.5

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Microstructure and mechanical properties of friction stir welded ... Gopi & Manonmani

Figure 3:

Micro-hardness at various heat inputs.

restricts the material flow while stirring. HW shows

higher value. This is due to the higher input, causes
material softening. But the grain size is very fine; this
is relatively equal in grain size produced in WOC and
the grains are disturbed due to the excess heat input.
3.3

Macrostructure

Figure 4 shows the macrostructure of friction stir

welds at different weld conditions. FSW originates
at the centre, WN; coalescence of two base metals has
been produced. Immediately at its side is the TMAZ
which ends at the tool shoulder. Outside of the TMAZ
there is zone affected only by the heat generated
during the welding process. Usually the entire weld
zone composing of WN and HAZ in FSW is by far
the smallest when compared to other fusion welds.
The conical shape at the centre in the macrostructure
establishes the TMAZ which comprises the WN at
the centre. This is difficult to identify in 6xxx series
aluminium alloys. The top surface of the cone is
relatively equal in size of the shoulder diameter
and similarly the bottom is equal in diameter of the
probe. The adjacent area which differs from TMAZ
and base metal is called HAZ. This is narrow in size
and adjacent to the conical side.

Figure 4:

Macrostructure at various heat inputs.

Figure 5:

Base material microstructure at

100 magnification.

WOC gives a defect-free weld with narrow WN,

and HAZ. CW shows the narrower weld zone with
stirring defect. The improper heat to overcome the
sticking friction causes the stirring defect in cold weld.
In HW the excess heat generation and friction free
tool rotation causes the wider weld zone and stirring
defect respectively (Gopi & Manonmani, 2012d).
3.4

Microstructure

The microstructure of the parent metal consists of

elongated grain morphology. This is shown in figure
5. It has higher hardness due to strain hardening effect
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Microstructure and mechanical properties of friction stir welded ... Gopi & Manonmani

by rolling. In FSW, three different microstructural

zones are identified such as WN, HAZ, and unaffected
base material. The WN zone experiences high strain
and is prone to recrystallisation. Immediately at its
side is the TMAZ which ends at the tool shoulder.
Outside of the TMAZ there is a zone affected only
by the heat generated during the welding process
(Scialpi et al, 2007; Woo et al, 2006). WN has a
recrystallised microstructure that consists of very fine
intensively stirred harmonised grains. These grains
are homogeneous at higher heat inputs/energy than
the lower heat inputs/energy. It occurs because of
sufficient heat input to form homogeneous grains.
Grain size of the nugget is decreasing with the increase
of heat input. TMAZ is characterised by rotation of the
elongated grains of the parent metal.
Figure 6 shows the microstructure of friction stir
welds at various heat inputs. The microstructure of
the WN at WOC shows very fine and harmonised
grains. At higher heat energy, ie. in HW, grain
refinement takes place. But the grains are distorted
due to lack of frictional contact between tool and
material. Whereas in CW the insufficient heat energy
restricts the material flow while stirring. This shows
the coarse grains in CW relatively.
From the microstructural observation by SEM as
shown in figure 7 and spectroscopy by energy
dispersive spectrometer results for WOC as shown

Figure 6:

135

in table 4, it was clear that the WN zone has

harmonised microstructure compared to other zones.
The WN zone had the least magnesium content and
magnesium silicide (Mg2Si) particles. Magnesium
markedly increases the strength of aluminium
without unduly decreasing the ductility. The HAZ
had greater silicon content which intensified grey
layer dispersion (Mrowka-Nowotnik et al, 2007).
The grey layer intensity was lesser in WN because
of fewer atomic percentage of silicon in it among the
three zones. Silicon, after iron, is the highest impurity
level in commercial aluminium. Silicon is used with
magnesium at levels up to 1.5% to produce Mg2Si.
Mg2Si has a high melting temperature, low density,
high hardness, low thermal expansion coefficient
and reasonably high elastic modulus (Gopi &
Manonmani, 2012b).
4

CONCLUSIONS

The tensile strength of CW was higher than the HW.

This is because of material softening obtained at
higher temperatures. CW is prone to brittle fracture.
The WOC has been comproised in both extreme weld
conditions of CW and HW and provides better results.
Hardness of WN, TMAZ and HAZ was lower at
higher heat inputs, and it varies uniformly across
the weld joint.

Microstructure at various heat inputs (SEM images in 100 magnifications).

Australian Journal of Mechanical Engineering

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Microstructure and mechanical properties of friction stir welded ... Gopi & Manonmani

The grain size of the WN at optimum heat input was

very fine and harmonised structure; compared with
two extreme heat levels such as HW and CW.

(a)

ACKNOWLEDGEMENT
The authors are grateful to the Departments of
Production Engineering, Mechanical Engineering
and Civil Engineering of Government College of
Technology, Coimbatore, India, for extending the
facilities to carry out the investigation.
REFERENCES
ASTM, 2006, Standard testing of metallic materials,
Annual book of ASTM standards.

(b)

Beraha, E. & Shpigler, B. 1977, Color Metallography,

American Society for Metals.
Cavaliere, P., Cerril, E. & Squillace, A. 2005,
Mechanical response of 2024-7075 aluminium alloys
joined by friction stir welding, Journal of Materials
Science, Vol. 40, No. 15, pp. 3669-3676.
Chao, Y. J. & Qi, X. H. 1998, Thermal and thermomechanical modeling of friction stir welding of
aluminium alloy 6061-T6, Journal of Material
Processing & Manufacturing Science, Vol. 7, No. 2, pp.
215-233.

(c)

Elangovan, K. & Balasubramanian, V. 2008a,

Influences of tool pin profile and welding speed
on the formation of friction stir processing zone
in AA2219 aluminium alloy, Journals of Materials
Processing Technology, Vol. 200, pp. 163-175.
Elangovan, K. & Balasubramanian, V. 2008b,
Influences of tool pin profile and shoulder diameter
on the formation of friction stir processing zone in
AA6061 aluminium alloy, Materials and Design, Vol.
29, pp. 362-373.
Figure 7:

Microstructures of WOC (SEM images

in 3000 magnifications) (a) WN,
(b) HAZ and (c) parent metal

Table 4:

Material spectrum by energy

dispersive x-ray spectrometer.

Element

Atomic (%)
WN

HAZ

Parent metal

OK

08.55

11.73

11.43

Mg K

00.99

01.14

01.07

Al K

89.58

86.13

86.38

Si K

00.66

00.84

00.88

Mn K

00.22

00.16

00.24

Australian Journal of Mechanical Engineering

Gopi, S. & Manonmani, K. 2012a, Optimization of

Process Parameters on Joint Strength of Friction Stir
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Microstructure and mechanical properties of friction stir welded ... Gopi & Manonmani

S GOPI
S Gopi received his BE degree in Production Engineering from Madras
University, Chennai, India, in 2001, and ME degree in Engineering Design
from Anna University, Chennai, India, in 2007. He is currently an Assistant
Professor at the Department of Production Engineering, Government College
of Technology, Coimbatore, India. He is a budding research scholar in the area
welding, especially friction stir welding. He has published papers in different
journals and conferences at national and international levels. His current work
covers welding techniques, element design and analysis, operation research,
optimisation techniques, and industrial automation.

K MANONMANI
K Manonmani received her BE degree in Mechanical Engineering, ME degree
in Engineering Design and PhD from Bharathiar University, India, in 1989, 1998
and 2007, respectively. She is currently an Associate Professor at the Department
of Mechanical Engineering, Government College of Technology, Coimbatore,
India. She has over 25 publications in different journals and conferences. Her
current research includes welding techniques, especially high energy welding
processes, as well as modelling of welding processes, vibration engineering,
non-traditional optimisation and finite element analysis.

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