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Open AccessArticle

Friction Stir Welding of T-Joints: Experimental and Statistical Analysis

Manufacturing Engineering Department, Modern Academy for Engineering and Technology, P.O. Box, Cairo 11571, Egypt
Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University, P.O. Box, Tanta 31512, Egypt
Mechanical Engineering Department, College of Engineering, United Arab Emirates University, P.O. Box, Al-Ain 15551, United Arab Emirates
On leave from Mechanical Design Department, Faculty of Engineering, El Mataria, Helwan University, P.O. Box, Cairo 11718, Egypt
Author to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2019, 3(2), 38;
Received: 3 April 2019 / Revised: 28 April 2019 / Accepted: 30 April 2019 / Published: 6 May 2019
T-welded joints are commonly seen in various industrial assemblies. An effort is made to check the applicability of friction stir welding for producing T-joints made of AA6063-T6 using a developed fixture. Quality T-joints were produced free from any surface defects. The effects of three parameters, such as the speed of rotation of the tool, axial force, and travel speed were analyzed. Correspondingly, mechanical characteristics such as tensile strength, hardness in three zones (thermal heat affected zone, heat affected zone, and nugget zone) and temperature distribution were measured. The full factorial analysis was performed with various combinations of parameters generated using factorial design and responses. Evident changes in the strength, hardness, and temperature profile were noticed for each combination of parameters. The three main parameters were significant in every response with p-values less than 0.05, indicating their importance in the friction stir welding process. Mathematical models developed for investigated responses were satisfactory with high R-sq and least percentage error. View Full-Text
Keywords: friction stir welding (FSW); T-joint; full factorial analysis; mechanical characteristics; temperature friction stir welding (FSW); T-joint; full factorial analysis; mechanical characteristics; temperature
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Sabry, I.; El-Kassas, A.M.; Mourad, A.-H.I.; Thekkuden, D.T.; Abu Qudeiri, J. Friction Stir Welding of T-Joints: Experimental and Statistical Analysis. J. Manuf. Mater. Process. 2019, 3, 38.

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