Mechanical and Metallurgical Evaluation of Friction Welded Joints Formed with Rotating Al 6063 with Flat Interface and Al 6082 with Taper Interface

DOI

10.2991/978-94-6463-922-3_31How to use a DOI?

Keywords

Rotary friction welding; Taguchi’s L9 orthogonal array; Dynamic recrystallization

Abstract

Rotary friction welding is a solid-state process in which two metal parts are joined by rotating them against each other under heat and pressure. It is widely used in aerospace, railroad, automotive, and chemical industries. In this work, Aluminium 6063 and Aluminium 6082 rods were joined using rotary friction welding. While the Al 6063 interface is maintained with a flat geometry, the Al 6082 interface is designed with a tapered profile. The objective of this work is to investigate the mechanical and microstructural characteristics of the dissimilar friction-welded joints produced using these interface configurations. An L9 orthogonal array was used to study the effect of tapered interface geometry along with friction pressure and friction time. The mechanical properties of the dissimilar friction-welded joints were evaluated using tensile and Vickers microhardness tests. The joint produced with a friction pressure of 37.5 MPa, a taper angle of 45°, and a friction time of 12 s achieved the highest tensile strength of 113.75 MPa, corresponding to 47% of the strength of Al 6063 and 40% of that of Al 6082. Analysis of the tensile test results shows that friction pressure has a greater influence on the strength of dissimilar friction-welded joints than the taper angle. Microstructural analysis shows that, from the parent material toward the weld interface, grains become elongated and finer due to dynamic recrystallization induced by heat and plastic flow. The weld zone exhibited the highest hardness among all regions, attributed to residual stresses.

Copyright

© 2025 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - P. M. Makesh
AU  - Baiju Sasidharan
AU  - Vineeth Narayanan
PY  - 2025
DA  - 2025/12/25
TI  - Mechanical and Metallurgical Evaluation of Friction Welded Joints Formed with Rotating Al 6063 with Flat Interface and Al 6082 with Taper Interface
BT  - Proceedings of the International Conference Recent Advances in Materials, Processes and Technology for Sustainability (RAMPTS 2025)
PB  - Atlantis Press
SP  - 471
EP  - 481
SN  - 2590-3217
UR  - https://doi.org/10.2991/978-94-6463-922-3_31
DO  - 10.2991/978-94-6463-922-3_31
ID  - Makesh2025
ER  -