Investigation of Joinability Of 25% Recycled Al6016 Sheets by Friction Stir Butt Welding at Different Tool Rotation Speed

Authors : Halil Kirdemir, Cihan Yakupoğlu, Faruk Varol, Serkan Apay
Pages : 1-12
Doi:10.52795/mateca.1553191
View : 89 | Download : 63
Publication Date : 2025-04-30
Article Type : Research Paper
Abstract :In this study, 2 mm thick Al6016 aluminum sheets containing 25% recycled material, commonly used in automotive body and chassis components, were joined using the friction stir welding (FSW) method in a butt joint configuration. Welding was performed on a mold milling machine using a conical tool made of 2379 grade steel, hardened to 62–64 HRC. Constant process parameters included a welding speed of 400 mm/min, tool plunge depth of 1.8 mm, shoulder diameter of 15 mm, and tool tilt angle of 90°. Tool rotation speeds were varied as 600, 1200, 1800, 2400, 3000, and 3600 rpm. Heat input was calculated for each condition. Mechanical performance of the joints was evaluated through tensile, bending, and hardness tests. Macro and microstructural examinations were also conducted, including fracture surface analysis. The highest tensile strength (214 MPa) was obtained at 1800 rpm, while the lowest (83 MPa) occurred at 600 rpm. In bending tests, no fractures were observed at 2400 and 3000 rpm, indicating good ductility and joint integrity. The highest hardness in the weld zone was 97.4 Hv, measured at 600 rpm. Macrostructural observations showed full penetration at all rotation speeds. Microstructural analysis revealed progressive grain refinement from the base metal toward the stir zone, confirming effective plastic deformation and recrystallization. The results demonstrate that tool rotation speed significantly affects joint quality. Optimal mechanical properties were achieved at intermediate speeds, particularly 1800 rpm, highlighting its potential for automotive applications involving recycled Al6016 sheets.
Keywords : Sürtünme karıştırma kaynağı, Geri dönüştürülmüş Al6016, C2379

ORIGINAL ARTICLE URL