Title: Friction stir welding of commercially pure aluminium alloy using

counter rotating twin tool

K.Kumari, Surjya K Pal
Department of Mechanical ngineering, !ndian !nstitute of Technology,
Kharagpur, !ndia
"#stract
"n attempt has #een made to study the effect of counter rotating twin tool on the commercially pure
aluminium alloy using friction stir welding. Further a comparati$e study is made #etween twin tool
%TT& and single tool using dou#le pass %ST'DP&.Twin tool helps in generating high heat caused
intense plastic deformation in the processed (one. Defect free (one not only depends on the
rotational speed #ut also on the com#ined effect of welding speed and rpm. )igher hardness profile
is o#ser$ed with highest welding and rotational speed %*+,, rpm with -. mm/min&.0oints fa#ricated
at higher rpm and higher welding speed are found to #e free from defects. Further .*.1 mm/min
welding speeds is the critical point where a sudden change in mechanical properties was o#ser$ed.
SM results confirm the e2istence of ductile failure with microscopic $oids of different shape and
si(es.
Keywords: Friction stir welding, counter rotating twin tool,
!ntroduction
specially for aluminium alloy, Friction stir welding is an impro$ed techni3ue of joining compared
to fusion welding process. !t is a solid state techni3ue where the temperature is reached #elow
melting point of the welding material, in$ented #y The 4elding !nstitute, in *55* %Mishra and Ma,
6,,1& and %7andan et al., 6,,+&.The process is ad$anced in joining materials which are difficult to
weld, re3uire no filler and shielding gas, need less s8illed wor8ers.
)owe$er, careful selection of welding process parameters %such as weld speed, rotation
speed, plunge depth or plunge force, tool geometry& which are comple2, is #eneficial for pre$enting
the formation of defecti$e weld %9eal and 9oureiro, 6,,:&.
Furthermore, some degradation in mechanical properties has #een o#ser$ed when there is a
de$iation in the welding condition. Though it is a relia#le techni3ue for joining, complete
elimination of defect is not possi#le. So a lot of researchers focussed to repair the defecti$e portion
#y using multi'pass FS4/FSP using the nominal process parameters. That means, #y using the re'
welding techni3ue, defecti$e portion of the weld is #eing repaired %;rown et al., 6,,5&. <ecent
literature reports se$eral e2amples related to multi'pass FSP/FS4.
%;rown et al., 6,,5& performed fi$e o$erlapping passes and found that there is no need of any
adjustment for multi'pass welding. Further there is a significant reduction in feed force when
welding is done o$er the pre$ious weld. )owe$er grain si(e, hardness and temperature during
welding is unaffected with num#er of passes. "gain there is a gradual reduction of residual stress
with increasing pass num#er.
%7ata8a et al., 6,,-& reported an ad$ancement of the mechanical properties in aluminium die
casting alloy using multi'pass FSP compared to the as'cast #ase metals. "s compared to #ase metal,
hardness increased #y 6,)=and the tensile strength of the multi'pass specimens were significantly
increased to a#out *.> times of as'cast #ase metal. The main reason for impro$ement of mechanical
properties is due to the remo$al of cold fla8e, uniform distri#ution of the silicon particles o$er the
aluminium matri2 which refines the grain. ?n the other hand %Ma et al., 6,,-& reported that there is
no effect of o$erlapping passes on si(e, aspect ratio or distri#ution of the Si particle while
performed fi$e'pass with 1,@ o$erlap FSP on cast ".-1.
%9eal and 9ouriero 6,,+& in$estigated the effect of o$erlapping FS4 passes using two "l alloys
%""1,+.'? and "" -,-.'T-&.They found that the 3uality and strength of the welded joint is not
only dependent on the weld parameters, #ut also on the type of material and its heat treatment
conditions. 9astly they found that weld polishing impro$ed the mechanical efficiency of the welded
joint.
"s FSP is one of the most promising techni3ues for grain refinement, remo$ing flaws, defectsA
many researchers used multi'pass FSP to impro$e the properties of as'cast material. %0ohannes and
Mishra 6,,>& used to demonstrate the effecti$eness of multiple passes to create large area of super
plastic materials with properties. They conclude that for achie$ing the super plastic deformation
grain #oundary sliding %B;S& is the most important mechanism. Similarly %Ma et al., 6,,5& noted
that two pass FSP shows enhanced super plastic elongation compared to single pass. Further the
temperature in central (one of second pass and transitional (one is more than the single pass.
%Sure8ha et al. 6,,+& reported that multi'pass FSP showed #etter corrosion resistance compared to
the #ase metal.
Csing cast "l alloy, %0ana et al., 6,*,& reported that multiple passes helped in remo$al of a#normal
grain growth %"BB& occurred during single pass runs. They also e2amined and found that higher
rotational speed was found to #e #eneficial for controlling the "BB. %;armou( and Bi$i, 6,**&
used MPFSP to impro$e metallurgical and mechanical properties of cu/sic metal matri2 composites.
<esult shows Sic particle dispersed and fragmented to smaller si(e due to se$ere stirring action in
the nugget (one of the copper matri2. !t also created strong interfacial #onding #y remo$ing the
porosity content.
Multi'pass o$erlapping FSP %MP? FSP& has #een applied #y %7i et al., 6,**& to transform the
coarse as'cast 7a# alloy #ase metal to get defect free material with fine microstructure, which was
feasi#le to modify the large si(ed plates. Similar type of study had #een conducted #y %!(adi and
Berich, 6,*6& to study the effect of multi'pass FSP on distri#ution and sta#ility of car#on nano'tu#e
and to fa#ricate "9 1,15 and M4D7Ts metal matri2 composite %MMD&.
To a$oid the use of multi'pass FS4/FSP, the two'tool'FS4 concept is #eing de$eloped at T4! in
se$eral $ariations %Thomas, *555&. ?ne of those techni3ues is named as Tandem twin'stir techni3ue
%Thomas et al., 6,,1&. Tandem Twin'Stir uses two FS4 tools %with or without counter rotation&
positioned one in front of the other.
The aim of this in$estigation to determine the effect of two contra rotating FS4 tool %Tandem
Twin'stir& on the friction stir processing/welding region of commercially pure aluminium alloys.
6. 2perimental wor8
!n order to demonstrate the characteristics of twin tool, a self designed twin tool setup is designed,
fa#ricated and used for friction stir welding is shown in Fig *. The twin tool system is composed of
two tools which are rotating in opposite direction to each other. The primary tool is mounted on the
main spindle shaft. Therefore, the main tool rotates at the same rotational speed and in the same
direction as the spindle during the welding process. The secondary tool is connected with the
primary tool with the help of gear assem#ly. The power transmission from the primary to secondary
tool is similar to the transmission of power from dri$er to dri$en gear, So that the rotation of the
secondary tool is just opposite to the primary tool.
Fig.*: Twin tool attachment
Friction stir welding using twin tool and single tool with dou#le pass were produced in 6.1 mm
thic8 plate of commercially pure **,, aluminium alloy. !n #oth the cases welds made with
complete o$erlapping passes. ;oth the plates were clamped using specially designed E2ture as
shown in Fig 6. The nominal chemical composition of the plate is shown in Ta#le *.The FS4
carried out at 8nee type $ertical milling machine %;F4, =F..1&, which has wide range of rotational
speed %:1 to *+,, rpm& and welding speed/feed rate %*- to +,, mm/min&.
Fig.6: Specially designed Fi2ture
Ta#le *.
Dhemical composition of the wor8 piece material
Dhemical composition %weight @& of wor8 piece material
Si Fe Du Mn Mg Fn Ti Ba 7a ?thers
<emainder
"luminium
,.>,11 .+.* .,,1,1 ,.,*. ,.,,:-1 ,.,,.* ,.,,:+ ,.,**+ ,.,,6:1
Ma2.
,.,1@
5+.>
" non'consuma#le tool made of stainless steel SS.*- with *- mm shoulder diameter, a cylindrical
pin of 1 mm diameter and 6 mm length was used for welding. ;y using four rotational speeds %5,,,
**6,, *:,,, *+,, rpm& and three welding speeds %*-, .*.1,-. mm/min&, total *6 e2periments were
performed using twin tool and single tool with dou#le pass. Therefore, total 6: e2periments ha$e
#een carried out at this stage. The coupled plate with simultaneous dou#le pass using the twin tool
setup is shown in Fig ..
Fig..: Schematic diagram of welded plate using twin tool setup
To e2amine the superficial defects macroscopic analysis was done using 9eica S-D Trinocular
stereo (oom microscope with 9eica G4in'=. image analysis software. Specimen for
metallographic analysis are sectioned comprising of welded (one, heat affected (one, thermo'
mechanical (one and unaffected #ase metal region. Samples are polished with a set of emery papers
with different grades. Further diamond paste is used for final polishing in $aria#le speed grinder
polishing machine. Kellers reagent was used to e2amine the macroscopic $iew. The ;uhlerHs
=ic8ers hardness indentation machine with 6,, gmf with *1 sec dwell time was used to get the
hardness profile of the welded sample on a cross section normal to the welding direction. To
e$aluate the tensile strength of the welded samples, specimens were cut using electro discharge
machine trans$erse to the direction of the weld line. The tensile test was carried out at normal room
temperature using !7ST<?7'++-6 machine with a ram speed of *mm/min. Fig : shows the
dimension of the tensile test specimen. The fractured tensile surfaces were studied using scanning
electron microscope %0?9'0SM 1+,,& to analyse the failure patterns.
Fig. :: Shape of the tensile test samples
.. <SC9TS
..* Macrostructural analysis
Porosity, solidification crac8ing, inclusions are some of the defects in fusion welding process
which degrades the 3uality of the weld and the property of the joint. Mainly these types of
defects are not generated in case of friction stir welding, in which there is no melting of metal
occurs. 0oining ta8es place due to the stirring action of metal and heat generation #y friction.
)owe$er due to improper selection of process parameters defects li8e pinhole, tunnels, piping
defect, 8issing #ond, crac8s are generated in the friction stir welded joints. Stereo (oom
microscope with magnification of *,I was used to analyse the 3uality of the welded region.
Macrostructure of the welded regions are shown in Fig 1 using twin tool attachment with
different rotational and welding speed. "t higher rpm and high welding speed joints using twin
tool shows defect free welds. )ence formation of defect free weld is #oth dependent on the
rotational speed and welding speed.
900-16
1120-16
1400-16 1800-16 900-31.5 1120-31.5
1400-31.5
1800-31.5 900-63
1120-63 1400-63
1800-63
Fig.1: Macrographs of welded samples using twin tool
..6 )ardness Testing
Fig 1 shows the hardness profiles of the welds made with twin tool as well as single tool with
dou#le pass. 4elds made with twin tool shows higher $alue of hardness compared to the two pass
FS4 joints for most of the welding parameters. This is due to the hardening effect caused #y
intense plastic deformation in the processed (one. "s materials in the nugget (one are su#ject to two
stirring actions so materials undergo se$ere plastic deformation due to which it gains a higher
cooling rate as compared to single pass material. 4ith su#se3uent processing of one tool o$er the
other intense plastic deformation is occurred #y which hardness caused due to second pass is more
than the first pass. Similarly in case of two pass using single tool, the material is su#jected to two
stir effects #ut there is a time delay in #etween the two passes. Therefore, cooling rate is somewhat
less as compared to twin tool passes. From the Fig 1 %l&, it is re$ealed that welds made with twin
tool shows higher hardness $alue compared to single tool with dou#le pass corresponding to *+,,
rpm with -. mm/min welding speed. Further from Fig 1 %a'l& it is o#ser$ed that at high rotational
speed of *+,, rpm with all constant welding speed, twin tool gi$es the higher $alue of hardness
profile in comparison to two pass using single tool. Fig > %a'd& shows the effect of welding speed on
a$erage micro hardness of welded samples at constant rpm. !t can #e seen that .*.1 mm /min is the
critical welding speed where there is drastic change in the a$erage micro hardness of a particular
sample with a definite welding parameter. So harness $alue is not only depends on the rotational
speed or welding speed it depends on the re$olutionary pitch i.e. %welding speed/rotational speed&
in mm per re$.
-10 -5 0 5 10
20
25
30
35
40
45
50
55
60
H
a
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s
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(
H
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Distance from weld centre (mm)
900-16()
900-16(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
30
35
40
45
50
55
H
a
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(
H
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Distance from weld centre (mm)
1120-16()
1120-16(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
15
20
25
30
35
40
45
50
H
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(
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Distance from weld centre (mm)
1400-16()
1400-16(!-D")
-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12
20
25
30
35
40
45
50
55
60

H
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s

(
H
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Distance from weld centre (mm)
1800-16()
1800-16(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
25
30
35
40
45
50
55
60
H
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s

(
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Distance from weld center (mm)
900-31.5()
900-31.5 (!-D")
-10 -5 0 5 10
20
25
30
35
40
45
50
H
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(
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Distance from weld centre (mm)
1120-31.5()
1120-31.5(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
10
15
20
25
30
35
40
45
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H
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(
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Distance from weld centre (mm)
1800-31.5()
1800-31.5(!-D")
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30
35
40
45
50
55
H
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(
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Distance from weld centre (mm)
1400-31.5()
1400-31.5(!-D")
-10 -5 0 5 10
25
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H
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Distance from t#e weld center (mm)
900-63()
900-63(!-D")
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30
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45
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H
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(
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Distance from weld centre(mm)
1120-63()
1120-63(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
30
35
40
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H
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(
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Distance from weld centre (mm)
1400-63()
1400-63(!-D")
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30
35
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H
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(
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Distance from weld centre (mm)
1800-63()
1800-63(!-D")
Fig.1 %a'l&: ffect of TT, ST'SP, and ST'DP on the nugget (one hardness
900-16 1120-16 1400-16 1800-16
35
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sam$le $arameter

!-D"
%eldin& s$eed 16mm'min(const.)
900-31.5 1120-31.5 1400-31.5 1800-31.5
30
35
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%eldin& s$eed 31.5 mm'min(const.)
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900-63 1120-63 1400-63 1800-63
30
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%eldin& s$eed 63 mm'min(const.)
H
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!am$le $arameter

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Fig.- %a'c&: ffect of rotational speed on a$erage micro hardness of FS4 (one using TT J
ST'DP
900-16 900-31.5 900-63
35
40
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(otational s$eed 900 (const.)
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Fig.> %a'd&: ffect of welding speed on a$erage micro hardness of FS4 (one using TT J ST'
DP
... Tensile testing
Fig + %a'l& shows all the comparati$e graphs corresponding to yield strength, ultimate tensile
strength, percentage of elongation and joint efficiency of the welded joints using twin tool
and single tool with dou#le pass. !t is seen that there is no significant $ariation in the yield
strength of the joints fa#ricated using twin tool and dou#le pass.
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Fig.+ %a'l&: ffect of TT and ST'DP on KS, CTS, @ age of elongation and joint efficiency of
the welded samples
Fig 5 shows the effect of rotational speed on yield strength at constant welding speed. !t is
seen that at a constant welding speed *+,, rpm shows higher yield strength in all the cases
using single tool with dou#le pass. Similarly from Fig.*, at a constant rotational speed -.
mm/min welding speed results higher yield strength using single tool with dou#le pass. ;ut
the $ariation in yield strength using #oth twin tool and single tool with dou#le pass at higher
rpm %*+,, rpm& and at higher welding speed %-. mm/min& is almost negligi#le. Further from
the comparati$e graphs it is o#ser$ed that .*.1 mm/min welding speeds is the critical point
where there is a sudden change in the mechanical strength for all the cases. This similar
scenario is o#ser$ed in case of ultimate strength, percentage of elongation and joint efficiency
also.
900-16 1120-16 1400-16 1800-16
35
40
45
50
)
!

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5
"
a
!am$le $arameter

!-D"
%eldin& s$eed816 mm'min(const.)

900-31.5 1120-31.5 1400-31.5 1800-31.5
30
35
40
45
50
55
60
%eldin& s$eed831.5 mm'min(const.)
)
!

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"
a
!am$le $arameter

!-D"
900-63 1120-63 1400-63 1800-63
38
40
42
44
46
48
50
%eldin& s$eed863 mm'min(const.)
)
!

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5
"
a
!am$le "arameter

!-D"
Fig. 5 %a'c&: ffect of rotational speed on yield strength of welded joints using TT J ST'DP
900-16 900-31.5 900-63
35
40
45
50
55
60
(otational s$eed8900 r$m(const.)
)
!

i
n

5
"
a
!am$le $arameter

!-D"

1120-16 1120-31.5 1120-63
25
30
35
40
45
50
55
60
(otational s$eed81120 r$m(const.)
)
!

i
n

5
"
a
!am$le $arameter

!-D"
1400-16 1400-31.5 1400-63
35
40
45
50
55
60
(otational s$eed81400 r$m(const.)
)
!

i
n

5
"
a
!am$le $arameter

!-D"

1800-16 1800-31.5 1800-63
30
35
40
45
(otational s$eed81800 r$m(const.)
)
!

i
n

5
"
a
!am$le $arameter

!-D"
Fig.*, %a'd&: ffect of welding speed on yield strength of welded joints using TT J ST'DP
900-16 1120-16 1400-16 1800-16
40
50
60
90
80
90
100
110
120
%eldin& s$eed16 mm'min (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"

900-31.5 1120-31.5 1400-31.5 1800-31.5
40
50
60
90
80
90
100
110
120
%eldin& s$eed 31.5 mm'min (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"
900-63 1120-63 1400-63 1800-63
90
95
80
85
90
95
100
%eldin& s$eed863 mm'min (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"
Fig.** %a'c&: ffect of rotational speed on CTS of welded joints using TT J ST'DP
900-16 900-31.5 900-63
40
50
60
90
80
90
100
110
120
(otational s$eed8900 r$m (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"

1120-16 1120-31.5 1120-63
40
50
60
90
80
90
100
110
120
(otational s$eed81120 r$m (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"
1400-16 1400-31.5 1400-63
60
90
80
90
100
110
120
(otational s$eed81400 r$m (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"

1800-16 1800-31.5 1800-63
60
90
80
90
100
110
120
(otational s$eed81800 r$m (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"
Fig.*6 %a'd&: ffect of welding speed on CTS of welded joints using TT J ST'DP
900-16 1120-16 1400-16 1800-16
0
5
10
15
20
25
30
35
40
%eldin& s$eed816mm'min (const.)
+

o
f

,
l
o
n
&
a
t
i
o
n

!am$le $arameter

!-D"

900-31.5 1120-31.5 1400-31.5 1800-31.5
0
5
10
15
20
25
30
35
40
%eldin& s$eed831.5 mm'min (const.)
+

o
f

,
l
o
n
&
a
t
i
o
n
!am$le $arameter

!-D"
900-63 1120-63 1400-63 1800-63
10
15
20
25
30
35
%eldin& s$eed863 mm'min (const.)
+

o
f

,
l
o
n
&
a
t
i
o
n
!am$le $arameter

!-D"
Fig.*. %a'c&: ffect of rotational speed on @age of elongation of welded joints using TT J
ST'DP
900-16 900-31.5 900-63
5
10
15
20
25
30
35
40
45
(otational s$eed8900 r$m (const.)
+

o
f

,
l
o
n
&
a
t
i
o
n
!am$le $arameter

!-D"

1120-16 1120-31.5 1120-63
0
5
10
15
20
25
30
35
40
45
(otational s$eed81120 r$m (const.)
+

o
f

,
l
o
n
&
a
t
i
o
n
!am$le $arameter

!-D"
1400-16 1400-31.5 1400-63
5
10
15
20
25
30
35
40
45
(otational s$eed81400 r$m (const.)
+

1
3

,
l
o
n
&
a
t
i
o
n
!am$le $arameter

!-D"

1800-16 1800-31.5 1800-63
20
22
24
26
28
30
(otational s$eed81800 r$m (const.)
+

o
f

,
l
o
n
&
a
t
i
o
n
!am$le $arameter

!-D"
Fig*: %a'd&: ffect of welding speed on @age of elongation of welded joints using TT J ST'
DP
900-16 1120-16 1400-16 1800-16
30
40
50
60
90
80
90
100
%eldin& s$eed816 mm'min (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"

900-31.5 1120-31.5 1400-31.5 1800-31.5
20
30
40
50
60
90
80
90
100
%eldin& s$eed831.5 mm'min (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"
900-63 1120-63 1400-63 1800-63
60
65
90
95
80
85
90
95
100
%eldin& s$eed863 mm'min (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"
Fig.*1 %a'c&: ffect of rotational speed on joint efficiency of welded joints using TT J ST'DP
900-16 900-31.5 900-63
30
40
50
60
90
80
90
100
(otational s$eed8900 r$m (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"

1120-16 1120-31.5 1120-63
20
30
40
50
60
90
80
90
100
(otational s$eed81120 r$m (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"
1400-16 1400-31.5 1400-63
50
60
90
80
90
100
(otational s$eed81400 r$m (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"

1800-16 1800-31.5 1800-63
50
60
90
80
90
100
(otational s$eed81800 r$m (const.)
0
o
i
n
t

e
:
c
i
e
n
c
;

i
n

+

a
&
e
!am$le $arameter

!-D"
Fig.*- %a'd&: ffect of welding speed on joint efficiency of welded joints using TT J ST'DP
!-D"
900-16
1120-16
1400-16
1800-16
900-31.5
1120-
31.5
1400-
31.5
1800-
31.5
900-63
1120-63
1400-63
1800-63
Fig.*>: "ppearance of the test pieces after tensile tests
Fig.*> shows the photographs of the test pieces after tensile testing using twin tool and single
tool with dou#le pass. From the figure it is seen that the fractured position in the weld reflects
the location of minimum hardness (one. This implies that the joint strength can #e correlated
with the micro hardness property.
..: Fractography
The fractured surface of the welded plate under tension is shown in the Ta#le . for twin tool
and single tool with dou#le passes. The presence of microscopic $oids of different si(e and
shape confirms the e2istence of ductile failure using scanning electron microscope. The
fractured surfaces of the tensile sample were populated with a large num#er of fine dimples
re$ealing failure due to ductile #eha$iour. This type of situation arises due to optimal material
mi2ing with grain refinement. ?n the contrary due to comple2 process parameter a less
ductile failure occur resulted in a less ductile failure or com#ination of ductile with #rittle
fracture or clea$age type. "t 5,, rpm and *- mm per min welding speed the welded
specimen shows different nature of fractured surface. Csing twin tool welded specimen is
fractured at the #ase metal (one #ut using single tool with dou#le pass the specimen #rea8s at
the weld (one region which shows partly ductile and partly #rittle fracture. Similarly with
twin tool the specimen #rea8s at the mid'(one of the weld region with *:,, rpm and *- mm
per min welding speed. The fractured surface shows a com#ination of ductile and clea$age
type fracture. Therefore when the specimen #rea8s at the weld (one or near#y (one the
fractured surface is the com#ination of ductile and #rittle fracture due to high heat generation
in that (one which causes intense plastic deformation.
Ta#le 6.
!mages of the fractured surface.
"<(<5,,( !-D"
900-16
1400-16
1800-31.5
900-63
1400-63
Donclusions
!n this in$estigation an attempt has #een made to study the effect of twin tool and single tool
with dou#le pass on the formation of friction stir welding (one in a commercially pure
aluminium alloy with different rotational speed and welding speed. From this, the following
conclusions are deri$ed:
*. Formation of defect free weld is a function of #oth rotational speed and welding
speed. 0oints fa#ricated at *+,, rpm and -. mm/min welding speed shows the highest
hardness profile compared to the other welded joints.
6. Further from the comparati$e graphs it is o#ser$ed that .*.1 mm/min welding speeds
is the critical point where there is a sudden change in the mechanical strength %yield
strength, ultimate tensile strength, percentage of elongation and joint efficiency& for
all the cases.
.. From the SM analysis it is o#ser$ed that the presence of microscopic $oids of
different si(e and shape confirms the e2istence of ductile failure.
<eferences
;armou(, M., Bi$i, M.K.;., 6,**. Fa#rication of in situ cu/sic composites using multi'pass
friction stir processing: $aluation of microstructural, porosity, mechanical and electrical
#eha$iour. Dompos part "'"ppl S, :6%*,&, *::1'*:1..
;rown, <., Tang, 4., <eynolds, ".P., 6,,5.Multi'pass friction stir welding in alloy >,1,'
T>:1*: ffects on weld response $aria#les and on weld properties. Mater Sci ng ", 1*.'
1*:, **1'*6*.
!(adi, )., Berlich, ".P., 6,*6. Distri#ution and sta#ility of car#on nanotu#es during multi'
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:>::':>:5.
0ana, S., Mishra, <.S., ;aumann, 0."., Brant, B., 6,*,. ffect of process parameters on
a#normal grain growth during friction stir processing of a cast "l alloy. Mater Sci ng ",
16+%*&, *+5'*55.
0ohannes, 9.;., Mishra, <.S., 6,,>. Multiple passes of friction stir processing for the creation
of super plastic >,>1 "luminium. Mater Sci ng ", :-:%*'6&, 611'6-,.
9eal, <., 9oureiro, "., 6,,:.Defects formation in friction stir welding of aluminium alloys.
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9eal, <.M., 9oureiro, "., 6,,+. ffect of o$erlapping friction stir welding passes in the
3uality of welds of aluminium alloys. Mater Design, 65%1&, 5+6'55*.
Ma, F.K., Sharma, S.<., Mishra, <.S., 6,,-. ffects of multiple'pass friction stir processing
on microstructure and tensile properties of a cast aluminium'silicon alloy. Scr. Mat. 1:%5&,
*-6.'*-6-.
Ma, F.K., Mishra, <.S., 9iu, F.D., 6,,5. Superplastic #eha$iour of micro'regions in two'pass
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Mishra, <.S., Ma, F.K., 6,,1. Friction stir welding and processing. Mater Sci ng < 1,, *'>+.
7andan, <., De#roy. T., ;hadeshia. ). K.D. )., 6,,+. <ecent ad$ances in friction stir
welding'process, weldment structure and properties. Prog Mater Sci. 1., 5+,'*,6..
7ata8a, K., Kim, K.B., Fujii, )., Tsumura, T., Koma(a8i, T., 6,,-. !mpro$ement of
mechanical properties of aluminium die casting alloy #y multi'pass friction stir processing.
Mater sci. ng ", :.>, 6>:'6+,.
7i, D.<., Iue, P., Ma, F.K., 6,**.ffect of Multiple'Pass Friction Stir Processing
?$erlapping on Microstructure and Mechanical Properties of "s'Dast 7i"l ;ron(e. Metall
Mater Trans ", :6%+&, 6*61'6*.1.
Sure8ha, K., Murty, ;.S., <ao, K.P., 6,,+.Microstructural Dharacteri(ation and corrosion
#eha$iour of multipass friction stir processed ""66*5 aluminium alloy. Surf Doat Tech, 6,6,
:,1>':,-+.
Thomas, 4.M., Staines, D.0., 4atts, .<., 7orris, !.M., 6,,1. The simultaneous use of two or
more friction stir welding tools, T4! 9td.report, Dam#ridge, CK.
Thomas, 4.M., *555. Friction Stir 4elding of Ferrous Materials: " feasi#ility Study,
Proceedings of the first !nternational Donference on Friction Stir 4elding, Thousand ?a8s,
D",T4!, paper on DD.