Friction stir welding of aluminum 6061 using varied probe

No doubt friction tool which is usually called as the probe has an important role in a Friction Stir Welding (FSW) process. To obtained good joint a suitable probe should be first provided. Four difference probe designs were evaluated in this article. The application of probe no.1 shows that the probe is too long and slender. The second probe then is developed where improvement was applied based on the results obtain from the first probe application. Using the second tool, the torsion is too high due to the large shoulder of the probe. The available belt and pulley system could not provide the needed torsion and belt slip was extremely exhibited which in turn caused the Friction Stir Welding (FSW) process is stoped. In the third probe, the shoulder diameter and pin were reduced and quenching heat treatment was applied to increase the strength. Using the third probe, quiet good appearance was obtained, but was not at full pertained length which was considered as heat shortage. Intermittent slip is occasionally also takes place. In the fourth probe diameter of the body was increased and chamfer was applied to reduce the shoulder surface. Insulator was also used to prevent heat lost. Using the last probe, the quiet good result was obtained over the whole pertained length.