Abstract
Welding is the process of creating a high-strength joint between two workpieces. Welding makes use of a number of techniques or processes, including melting base metal and loading it with filler material, using electron beams, utilizing lasers etc. One of the most recent welding techniques is friction stir welding (FSW). Friction stir welding is a joining process in which a non-consumable rotating tool plunges between workpieces which are rigidly fixed with clamps and moves along the join to be welded. Workpieces composed of aluminum 6061 with a size of 2 x 6 in and a thickness of 0.125 in were selected. Aluminum workpieces were joined by friction stir welding with the tool spindle speed being varied from 800 rpm to 1200 rpm, and the tool feed rate being varied from 4.4 in/min. to 8 in/min. The experiments were conducted using a Megastir E20261 FSW tool. Analysis of the workpieces was undertaken by testing the tensile strengths of the welded joints. Variations in the strength of the weld joints associated with diverse parameters is discussed.