Materials and Design 40 (2012) 716

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Materials and Design

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Technical Report

Effect of tool rotational speed and pin prole on microstructure

and tensile strength of dissimilar friction stir welded AA5083-H111
and AA6351-T6 aluminum alloys
R. Palanivel a,, P. Koshy Mathews b, N. Murugan c, I. Dinaharan d
a
Department of Mechanical Engineering, Kalaivani College of Technology, Coimbatore 641 105, Tamil Nadu, India
b
Research and Development, Kalaivani College of Technology, Coimbatore 641 105, Tamil Nadu, India
c
Department of Mechanical Engineering, Coimbatore Institute of Technology, Coimbatore 641 014, Tamil Nadu, India
d
School of Mechanical Sciences, Karunya University, Coimbatore 641 114, Tamil Nadu, India

a r t i c l e i n f o a b s t r a c t

Article history: The relatively new welding process friction stir welding (FSW) was applied in this research work to join
Received 14 January 2012 6 mm thick dissimilar aluminum alloys AA5083-H111 and AA6351-T6. The effect of tool rotational speed
Accepted 16 March 2012 and pin prole on the microstructure and tensile strength of the joints were studied. Dissimilar joints
Available online 23 March 2012
were made using three different tool rotational speeds of 600 rpm, 950 rpm and 1300 rpm and ve dif-
ferent tool pin proles of straight square (SS), straight hexagon (SH), straight octagon (SO), tapered
square (TS), and tapered octagon (TO). Three different regions namely unmixed region, mechanically
mixed region and mixed ow region were observed in the weld zone. The tool rotational speed and
pin prole considerably inuenced the microstructure and tensile strength of the joints. The joint which
was fabricated using tool rotational speed of 950 rpm and straight square pin prole yielded highest ten-
sile strength of 273 MPa. The two process parameters affected the joint strength due to variations in
material ow behavior, loss of cold work in the HAZ of AA5083 side, dissolution and over aging of pre-
cipitates of AA6351 side and formation of macroscopic defects in the weld zone.
2012 Elsevier Ltd. All rights reserved.

1. Introduction Friction stir welding (FSW) is an appropriate solid state welding

Many specic properties of aluminum alloys including light
weight and good structural strength enable them to be applied
for structural parts. The demand of aircraft and automotive indus-
tries for light weight materials is met by aluminum alloys. The alu-
minum alloys AA6XXX and AA5XXX are extensively used in the
fabrication of aircraft structures and other structural applications
[1]. Dissimilar welding of these two alloys is frequently faced in
those structures. Structural parts and frames composed of these
aluminum alloys can be welded using sound welding techniques
commonly used in industries. But conventional fusion welding of
aluminum alloys results in numerous welding defects which in-
cludes voids, hot cracking, distortion, precipitates dissolution, loss
of work hardening and lack of penetration in the joints [2,3]. There-
fore, solid state bonding technique is highly recommended to solve
those problems.
Corresponding author. Mobile: +91 9943707552; fax: +91 422 2575020.
E-mail addresses: rpalanivelme@gmail.com, rpalanivel@kvctmail.in
(R. Palanivel), pkoshymathews@yahoo.co.in, pkoshymathews@kvctmail.in
(P. Koshy Mathews), drmurugan@hotmail.com, murugan@cit.edu.in (N. Murugan),
dinaweld2009@gmail.com, issacdinaharan@karunya.edu (I. Dinaharan).
technique to effectively join any combination of dissimilar alumi-
num alloys [4]. FSW was invented at The Welding Institute
(TWI), UK in 1991. A nonconsumable rotating tool harder than
the base material is plunged into the abutting edges of the plates
to be joined under sufcient axial force and advanced along the
line of the joint. The tool consists of two parts namely shoulder
and pin. The material around the tool pin is softened by the fric-
tional heat generated by the tool rotation. Advancement of the tool
pushes plastically deformed material from front to back of the tool
and forges to complete the joining process [5]. Since FSW is a solid
state process, a solidication structure is absent in the weld. There-
fore, all the defects related to the presence of brittle inter dendritic
and eutectic phases are eliminated [6]. The major FSW process
parameters which inuence the joint strength and microstructure
are tool rotational speed, welding speed, axial force and tool tilt an-
gle [7]. The dimensions and shape of the tool play a crucial role to
obtain sound joints. The tool design signicantly alters material
ow and consolidation of plasticized material during welding [8].
Some studies on FSW of dissimilar AA5XXX and AA6XXX joints
were reported in the literatures [919]. Shigematsu et al. [9] at-
tempted to join 3 mm thick dissimilar AA5083 and AA6061 alloys
using FSW and examined the microstructure and the mechanical

0261-3069/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.matdes.2012.03.027
8 R. Palanivel et al. / Materials and Design 40 (2012) 716

Table 1
Chemical composition of AA6351-T6 and AA5083-H111.

Aluminum alloy Si Zn Mg Mn Fe Cu Ti Al
AA6351-T6 0.907 0.89 0.586 0.65 0.355 0.086 0.015 Balance
AA5083-H111 0.045 0.04 4.76 0.56 0.14 0.02 0.054 Balance

properties of the joint. Peel et al. [10] investigated the processing Table 3
window of 3 mm thick AA5083 and AA6082 joints and found that Welding parameters.
the tool rotational speed strongly inuenced the heat generation Process parameters Values
during welding than the traverse speed. Peel et al. [11] studied
Tool rotational speed (rpm) 600, 950 and 1300
the effect of tool rotational speed and traverse speed on the micro- Welding speed (mm/s) 60
structure, hardness and precipitate distribution of 3 mm thick Axial force (kN) 8
AA5083 and AA6082 joints. Steuwer et al. [12] quantied the effect Tool tilt angle () 0
of tool rotational speed and traverse speed on the residual stress of Tool shoulder diameter (mm) 18
Tool shoulder surface Flat
3 mm thick AA5083 and AA6082 joints. He concluded that the tool
Pin diameter (mm) 6
rotational speed was a useful process variable to optimize the Pin length (mm) 5.7
residual stress. Leal et al. [13] elaborated the inuence of tool Pin prole* SS, SH, SO, TS and TO
shoulder geometry on material ow in 1 mm thick AA5182-H111 Tool material High carbon high chromium steel
Tool hardness (HRC) 63
and AA6016-T4 joints. A tool shoulder with a conical cavity was re-
ported to yield an onion ring structure. Leitao et al. [14] analyzed *
SS straight square; SH straight hexagon; SO straight octagon; TS tapered
the tensile behavior of 1 mm thick AA5182-H111 and AA6016-T4 square and TO tapered octagon.
joints and observed that the grain size in the TMAZ and precipitate
distribution inuenced the tensile behavior. Leitao et al. [15] as-
sessed the formability of 1 mm thick AA5182-H111 and AA6016-
T4 joints by deep drawing cylindrical cups and noticed that the
mismatch in mechanical properties between the weld and the base
materials determined the formability limits. Park et al. [16] inves-
tigated the effect of material locations on the properties of 2 mm
thick AA5052-H32 and AA6061-T6 joints and observed a proper
mixing of dissimilar aluminum alloys when AA5052-H32 was kept
in the advancing side. Aval et al. [17] estimated the effect of tool
geometry on 5 mm thick AA5086-O and AA6061-T6 joints. He used
three tool geometries and found that the tool with a concave
shoulder and a conical probe with three grooves provided more Fig. 1. Fabricated FSW tools.
homogeneous stir zones compared to other tools due to higher
heat input. Aval et al. [18] used nite element software to predict pendicular to the rolling direction of AA6351-T6. This joint choice
the thermo-mechanical behaviors of 5 mm thick AA5086-O and was made to induce the most severe mechanical combination [20].
AA6061-T6 joints and compared the simulation results with the The welding parameters and fabricated tools are presented in Table
observed microstructures. Aval et al. [19] evaluated the thermo 3 and Fig. 1, respectively. The dissimilar butt welding was carried
mechanical behavior and microstructural events of 5 mm thick out automatically in an indigenously built FSW machine (M/s RV
AA5086-O and AA6061-T6 joints and observed that the tempera- Machine Tools, Coimbatore, INDIA).
ture eld was distributed asymmetrically resulting in larger ther- Specimens were cut from the welded plates perpendicular
mally affected region in the AA6061 side. to FSW line to carry out microstructural characterization. The
In this work, an attempt is made to join 6 mm thick aluminum specimens were prepared as per standard metallographic proce-
alloys AA5083-H111 and AA6351-T6 using FSW and investigate dure and etched with modied Keller reagent followed by Wecks
the inuence of tool rotational speed and pin prole on the micro- reagent. The digital image of the macrostructure of the etched
structure and tensile strength of the dissimilar joints. specimens was captured using a digital optical scanner.
The microstructure was observed using an optical microscope
2. Experimental procedure (OLYMPUS-BX51M). The tensile specimens were prepared as per
ASTM E8 standard having a gauge length of 40 mm, a gauge width
Aluminum alloys AA6351-T6 and AA5083-H111 which have of 7 mm and a thickness of 6 mm [21]. Three such tensile speci-
the chemical compositions and mechanical properties listed in mens were prepared from each joint and the average value of
Tables 1 and 2, respectively were used in this research work. Plates ultimate tensile strength (UTS) was taken. The UTS was estimated
of size 100 mm X 50 mm X 6 mm were prepared from the rolled using a computerized universal testing machine (HITECH
plates. AA6351-T6 and AA5086-H111 were respectively kept in TUE-C-1000).
the advancing side and retreating side of the joint line. The FSW
line was parallel to the rolling direction of AA5083-H111 and per-
3. Results and discussions

Table 2 FSW of 6 mm thick aluminum alloys AA5083-H111 and

Mechanical properties of AA6351-T6 and AA5083-H111. AA6351-T6 was accomplished. The two aluminum alloys have dif-
ferent ow stress. Aluminum alloy AA5083 offers more resistance
Base material UTS (MPa) Yield strength (MPa) Percentage elongation
to plastic ow compared to AA6351 [22]. Certain combinations of
AA6351-T6 310 285 14
tool rotational speed and pin prole yielded sound welds. The
AA5083-H111 308 273 23
crown appearance of dissimilar welds using different pin proles
 R. Palanivel et al. / Materials and Design 40 (2012) 716 9

Fig. 2. Crown appearances of dissimilar welds obtained at tool rotational speed of 950 rpm using tool pin proles: (a) SS; (b) SH; (c) SO; (d) TS and (e) TO.

at tool rotational speed of 950 rpm is shown in Fig. 2. Semicircular 3.1. Macrostructure and microstructure of dissimilar joints
features which are identical to those produced during conventional
milling process are seen on the crown. The formation of those fea- The macrostructure of all the fteen dissimilar joints are
tures is due to rubbing of FSW tool shoulder on the plates to be revealed in Fig. 3. It is evident from the gure that the joints fabri-
joined. Ceschini et al. [23] described the formation of such features cated at all tool rotational speeds using tool pin proles SS, SH and
induced by FSW as wake effect. The crown presents smooth
appearance without the presence of voids, cracks, depressions
and excessive ashes. The tool shoulder design helps to obtain
such a crown appearance. The tool shoulder design adopted in this
study is identical for all tool pin proles. The tool shoulder as
shown in Fig. 1 has at surface and three concentric grooves of
depth 1 mm and width 2 mm. This tool design is an optimized de-
sign to conventional conical shoulder and complete at shoulder.
The at surface and three concentric grooves serve the same func-
tions of conical shoulder which is easy to manufacture similar to a
complete at shoulder. The cavity in a concave shoulder is required
for the following causes; (i) to form a compressed annular ring of
work piece material around the tool pin; (ii) to prevent the escape
of plasticized material and (iii) to direct the material ow towards
the pin [24]. In the present work, the three concentric grooves
perform the same role of the cavity in a concave shoulder and pro-
duce sound joints. Fig. 3. Macrostructure of the welded dissimilar joints.
10 R. Palanivel et al. / Materials and Design 40 (2012) 716
SO are defect free. A tunnel at the bottom of the joint is always
present when tapered tool pin proles are used at all tool rota-
tional speeds. A sound joint forms when proper combinations of
those factors are met with. The two process parameters, tool rota-
tional speed and pin prole which are considered in this present
work contributes remarkably to the generation of frictional heat
during welding [25]. The rubbing of tool shoulder on the work
piece develops frictional heat. As tool rotational speed increases
the frictional heat also increases due to increased residing time
of tool. The macrostructures suggests that sufcient frictional heat
is formed to plasticize both the aluminum alloys at all tool rota-
tional speeds using straight pin proles which yielded defect free
welds. A straight pin prole tool has more contact area compared
to tapered tool. The transportation of plasticized material from
advancing side to retreating side is uniform from top to bottom
of the joint when straight pin prole tool is employed. The interac-
tion between tool and plasticized material is less in tapered pin
Fig. 4. Microstructure of various regions in the weld zone as marked in the macrostructure using SS tool pin prole at 950 rpm: (a) unmixed region; (bd) mixed ow region
and (e) mechanically mixed region.
prole tool owing to lesser contact area. The material swept across
the depth of the joint is nonuniform and affects regular material
ow characteristics. As a result, the shoulder experience lesser grip
on the plasticized material and sliding condition is promoted over
sticking condition. Therefore as the weld proceeds, a drop in fric-
tional heat is experienced. Because, sliding condition generates les-
ser heat than that of sticking condition [8]. Inadequate sweeping of
plasticized material and reduction in frictional heat leave a tunnel
at the bottom of the joint.
The microstructure of the weld zone obtained using different
tool pin proles at tool rotational speed of 950 rpm is presented
in Figs. 48. It is evident from these gures that the microstructure
of the dissimilar joint is dependent to a large extent on the position
within the weld zone. Different microstructures are observed while
moving across the breadth and depth of the weld zone. All the
observed microstructures can be categorized into three different
regions namely unmixed region, mechanically mixed region and
 R. Palanivel et al. / Materials and Design 40 (2012) 716
mixed ow region. The mixed ow region is absent in the joints
fabricated using tapered pin proles. The same region is also not
present in the joints fabricated using straight pin proles at tool
rotational speed of 650 rpm. The formation of three kinds of re-
gions within the weld zone agrees to the reporting of some inves-
tigators in dissimilar friction stir welded aluminum alloys
[26,9,17].
The formation and characterization of the three regions are de-
tailed as follows. To begin with, the unmixed region (Figs. 4a, 5a,
6a, 7a and 8a) contains the microstructure of either AA5083 or
AA6351. This region is observed at the top of the joints closer
to shoulder region. The ne grain structure indicates that this
unmixed region experienced dynamic recrystallization during
welding. Secondly, the mechanically mixed region (Figs. 4e, 5e,
6e, 7b and c and 8b and c) contains the microstructure of both
the aluminum alloys. The etchant reveals AA5083 as darker and
AA6351 lighter in color. The plasticized dissimilar alloys are
Fig. 5. Microstructure of various regions in the weld zone as marked in the macrostructure using SH tool pin prole at 950 rpm: (a) unmixed region; (bd) mixed ow region
and (e) mechanically mixed region.
11
mechanically coupled to each other. The penetration of one alu-
minum alloy into the other is not fully accomplished. But dy-
namic recrystallization of grains is evident. Finally, the mixed
ow region (Figs. 4bd, 5bd, 6bd) contains a structure of alter-
native lamellae of both the aluminum alloys. A complex vortex
like ow pattern is visible. The mixed ow region presents ex-
treme super plastic ow of plasticized material which creates
chaotic intercalation patterns. The stirring action of the tool
causes intense plastic deformation and in situ extrusion of alumi-
num alloys AA6351 and AA5083. The plasticized material is trans-
ported layer by layer which forms such a lamellae structure. The
penetration and mixing of both the aluminum alloys in this re-
gion is intense.
The structure of mixed ow region obtained using SS tool pin
prole differs slightly with those obtained using SH and SO tool
pin proles. Almost equal number of alternative lamellae of
AA5083 and AA6351 alloys is visible using SH and SO tool pin
12 R. Palanivel et al. / Materials and Design 40 (2012) 716

Fig. 6. Microstructure of various regions in the weld zone as marked in the macrostructure using SO tool pin prole at 950 rpm: (a) unmixed region; (bd) mixed ow region
and (e) mechanically mixed region.

proles. All the straight tools employed in the present work have
at surfaces. The geometry of the tool pin prole is uneven com-
pared to a round or threaded tool which inuences the plasticized
material ow behavior. A at tool creates a pulsating stirring ac-
tion due to the associated eccentricity [27]. The pulsating stirring
action offers resistance to the regular ow of plasticized material
which generates additional frictional heat. Consequently, the
material is more plasticized. SS, SH and SO tool pin proles pro-
duce 63, 95 and 127 pulses/s, respectively at tool rotational speed
of 950 rpm. The intensity and duration of the pulse are inversely
proportional to the number of at faces in a straight tool. There-
fore, SS tool pin prole produces high intense and long duration
of pulse compared to other straight tool pin proles which results
in severe and random layer by layer transfer of material (Fig. 3b
d). The pulsating action of SO tool is weak because the tool pin pro-
le approaches closer to cylindrical shape. On the other hand, the
tapered pin prole tools are ineffective to produce pulsating stir-
ring action and layer by layer transfer of plasticized material.
Hence, the mixed ow region is not present.
The formation of mixed ow region is further observed to be
dependent on tool rotational speed. The mixed ow region is ab-
sent at tool rotational speed of 600 rpm (The microstructure of un-
mixed and mechanically mixed regions is similar to those regions
observed at tool rotational speed of 950 rpm. Hence, no separate
microstructure is presented). Alvarez et al. [28] also noticed the ab-
sence of mixed ow region at tool rotational speed of 400 rpm in
dissimilar friction stir welded AA7075AA2024. It is mentioned
earlier that the tool rotational speed determines the generation
of frictional heat and amount of plasticized material. The volume
of plasticized material and interaction of tool is lower at tool
rotational speed of 600 rpm. Hence, the mixed ow region is not
formed.
 R. Palanivel et al. / Materials and Design 40 (2012) 716
Fig. 7. Microstructure of various regions in the weld zone as marked in the macrostructure using TS tool pin prole at 950 rpm: (a) unmixed region; (b) and (c) mechanically
mixed region.
3.2. Tensile properties of dissimilar joints
The effect of tool rotational speed and tool pin prole on the
tensile strength of the dissimilar joints is depicted in Fig. 9. It is
evident from the gure that the joints fabricated using tool rota-
tional speed of 950 rpm exhibit highest tensile strength for all tool
pin proles. Among the ve tool pin proles studied, joints fabri-
cated using SS pin prole yielded highest tensile strength. The frac-
ture location of some of the dissimilar joints is shown in Fig. 10.
The dissimilar joint failed in any one of the following locations:
(i) weld zone, (ii) HAZ of AA5083 side and (iii) near TMAZ of
AA6351 side.
The factors which determine the tensile strength of dissimilar
aluminum alloy joints are: (i) presence of macroscopic defects in
weld zone, (ii) degree of plastic ow and amount of mixing of both
the materials, (iii) grain size in HAZ, (iv) degree of dissolution and
over aging of precipitates. The joints fabricated using tapered pin
proles yielded poor tensile strength due to macroscopic defects
present in the weld zone at all tool rotational speeds. The joints
fabricated using straight pin proles at tool rotational speed of
950 rpm yielded highest tensile strength due to intense plastic
ow and mixing of dissimilar alloys which results in smooth hard-
ness variation across the joint. The tensile strength of joints fabri-
cated at tool rotational speed of 600 rpm using straight pin
proles is lower due to softening of HAZ of AA5083 side. At higher
tool rotational speed of 1300 rpm, dissolution and over aging of
precipitates occur which reduce the tensile strength. A dissimilar
weld can be considered as a good quality weld if failure takes
place in the weaker of the two dissimilar materials away from
13
the weld zone [29]. All the fteen joints failed to satisfy this ideal
condition. The macroscopic defects caused the joints to fail in the
weld zone. Failure in the HAZ of AA5083 side can be attributed to
loss of cold work in the HAZ due to annealing effect. Dissolution
and over aging of precipitates led the joint to fail near TMAZ of
AA6351 side.
The fracture surfaces of tensile tested dissimilar weld speci-
mens using different pin proles at tool rotational speed of
950 rpm is shown in Fig. 11. All the fracture surfaces are covered
with a large population of microscopic voids which vary in size
and shape. Some at zones are visible in the fracture surfaces of
dissimilar welds fabricated using tapered tools. The failure of the
dissimilar joint is dictated by the coalescence of those microscopic
voids in all cases. The observed failure mode is ductile brous frac-
ture. The depth of microscopic voids using tapered tools is lower
compared to those using straight tools which can be attributed
to the early coalescence of prematurely grown micro voids.
4. Conclusions
In the present work, the inuence of tool rotational speed and
pin prole on the microstructure and tensile strength of the dis-
similar friction stir welded aluminum alloys AA5083-H111 and
AA6351-T6 were investigated. The joints fabricated using straight
tool proles had no defects while tapered tool proles caused a
tunnel defect at the bottom of the joints under the experimental
conditions considered. Three different regions namely unmixed
region, mechanically mixed region and mixed ow region were
14 R. Palanivel et al. / Materials and Design 40 (2012) 716

Fig. 8. Microstructure of various regions in the weld zone as marked in the macrostructure using TO tool pin prole at 950 rpm: (a) unmixed region; (b) and (c) mechanically
mixed region.

Fig. 10. Fractured tensile specimens: (a) failed at weld zone; (b) failed at HAZ of
AA5086 side and (c) failed near TMAZ of AA6351 side.

Fig. 9. Tensile strength of dissimilar welded joints.

Acknowledgements

observed in the weld zone. The tool rotational speed and pin prole
inuenced the formation of mixed ow region. The joints fabri-
cated using tapered tool proles and tool rotational speed of
600 rpm showed absence of mixed ow region. The joint fabricated
using tool rotational speed of 950 rpm and straight square pin pro-
le yielded highest strength of 273 MPa. The variation in tensile
strength of the dissimilar joints was attributed to material ow
behavior, loss of cold work in the HAZ of AA5083, dissolution
and over aging of precipitates of AA6351 and formation of macro-
scopic defects in the weld zone.
The authors are grateful to the Management and Department of
Mechanical Engineering, Coimbatore Institute of Technology,
Coimbatore, India. The authors also acknowledge the nancial sup-
port rendered by Naval Research Board, Govt. of India. One of the
authors, Mr.I. Dinaharan acknowledges Department of Science
and Technology, Govt. of India for providing INSPIRE fellowship.
The authors are also thankful to Mr.S. Gopalakrishnan, Mr.S.J. Vijay,
Mr.M. Balakrishnan, Mr.R. Sathis Kumar, Mr.G. Sivakumar and Dr.
Shibu M. Eapen for their assistance offered to execute the above
work.
 R. Palanivel et al. / Materials and Design 40 (2012) 716 15

Fig. 11. Fracture surfaces of dissimilar welds obtained at tool rotational speed 950 rpm using tool pin proles: (a) SS; (b) SH; (c) SO; (d) TS and (e) TO.

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