Microstructure and Mechanical Properties of FSWed Aluminum Extrusion with Bobbin Tools

Bobbin FSW technique is assessed in terms of process productivity and robustness considering the metallurgical and mechanical qualities of the joint. Several different designed bobbin tools were applied to aluminium A6xxx alloy extrusions, at feed rate of 400-1000mm/min with tool rotation speed of 600-1000rpm. In case of A6068-T6, a joint efficiency of 68% was achieved at 600mm/min, which is almost equivalent to the productivity and quality of the conventional FSWed joints, hence the potential of bobbin FSW technique was suggested. The bobbin tool design was further optimized considering the practical process robustness to the part fit issue, and defect free welds have been achieved for the joints with a set gap up to 1 mm. However, the oxide remnant, so called lazy S was observed in a joint made with an inadequate designed tool, which significantly deteriorates the mechanical properties.