Study of friction stir welding parameters in conventional milling machine for 6082-T6 aluminium alloy

A conventional milling (CM) machine is capable of inducing the same axial force parameter as that of a friction stir welding (FSW) machine. In a CM machine, tool shoulder penetration, an alternate parameter instead of axial force of FSW machines, was used to carry out FSW joints. The process parameters such as spindle speed, welding speed, shoulder penetration, pin profile and shoulder profile at five levels were studied. With Taguchi orthogonal array, the process parameters were optimised to maximise the tensile strength of the FSW joint. From the investigation, it was found that the 1100 rpm spindle speed, hexagonal pin profile and 0.15 mm shoulder penetration reveals good results. Metallographic studies were carried out with a scanning electron microscope and energy dispersive x-ray spectrometer.