IMPACT OF TOOL WEAR ON THE UTMOST TEMPERATURE DURING THE FRICTION STIR WELDING

Abstract

Friction stir welding (FSW) is a solid-state welding method that involves joining two workpieces by applying pressure and significant plastic deformation close to their melting temperatures. The impact of rotation speed, travel speed, axial force, maximum temperature, and tool wear in the friction stir welding (FSW) process is significant. The present study examines the impact of three specified variables on the maximum temperature, ultimate tensile strength (UTS), and tool wear of friction stir welding (FSW) of 6063-T6 and 6060-T6 alloys. Response Surface Methodology (RSM) has been employed as an auxiliary method. The total amount of material removed from the tool wear was found to be directly proportional to the rotational speed but inversely proportional to the travel speed and axial force. The increase in rotation speed leads to higher tool wear but reduces the surface roughness of the tool. The findings indicate that the parameter with the most significant impact on the maximum attained temperature is 1800 rpm rotation speed and 4 mm/min travel speed, I KN axial force.