Statistical Analysis of Friction-Stir Welding of Al- 6063 Alloys

Aluminum 6063 alloys are widely used in various engineering and industrial applications since they are highly corrosion resistant and exhibit superior mechanical properties. They are often used in extrusion projects because of their, weldability, moderate strength and good workability. These properties allow them to excel in architectural applications, piping, tubing, general extrusions for medical, automotive, parts profiling, building and construction, recreational equipment and furniture. Investigations revealed that joining of these alloys by conventional welding techniques has several limitations. Friction Stir Welding (FSW) is a highly efficient manufacturing process with improved safety due to absence of toxic fumes or molten spatters and also end products with reduced weld defects, better retention of mechanical properties, less distortion and less residual stress. The present work focuses mainly on the characterization of friction stir welded joints of Al 6063 alloys using reconfigured Vertical Milling Machine. Brinell Hardness, Impact strength & Fractography study of the weldments were carried out to analyze the hardness, impact strength and microstructure of the weld zone and heat affected zone. To justify the impact of contribution of input parameters over the process outcome, Minitab -17 statistical modeling analysis was carried out.