Non-Destructive Testing and Evaluation of Friction Stir Welded AA6063 Circularly Butted Pipes

Friction stir welding of pipes is gaining research interest as it delivers high performance weld joints when compared to fusion welding techniques. Mechanical testing of such welded pipes will yield only results about mechanical behaviour but cannot detect the defects. An attempt has been made in employing non-destructive techniques in analysing the defects in Aluminium Alloy 6063 pipe joint obtained using friction stir welding. Three different tool pin profiles have been used in this study. The non-destructive testing methods employed helped to show the variation in the quality of the welds achieved through the three different tool pin profiles. Dye penetrant testing has been used in assessing the surface defects where solvent removable penetrant SKL-SP1 has shown evident results. Radiographic testing has been used in assessing root side defects. Tool with taper cylindrical pin along with tool rotational speed of 2000 rpm and weld speed of 0.6 rpm has produced weld with minor defects based on liquid penetrant and radiographic test results. Also the capability of non-destructive techniques in analysing the defects produced through friction stir welding has also been evaluated and presented.