Monitoring of friction stir welding for dissimilar Al 6063 alloy to polypropylene using sensor signals

  • Santosh K. Sahu
  • Kamal PalEmail author
  • Raju P. Mahto
  • Padmanav Dash


The present work addresses the feasibility of friction stir butt welding of dissimilar Al6063 to polypropylene for cylindrical and threaded tool pin profile at different tool positions like tool offsetting and slotted edge–based base plate design as bridle joint to improve the weld quality. The new slotted edge–based design using threaded tool pin profile was found to be highly efficient. This work was further extended with the interaction effect of tool rotational speed and traverse speed. The major objective was to investigate the variation of axial force and torque due to the parametric variation, especially to find the correlation with weld quality characteristics. The mean and standard deviation of axial force and torque indicated the formability and material mixing capability during welding which in turn found to be highly correlated to weld bead uniformity. The joint behavior due to tensile load and bonding mechanism in weld stirred zone have been studied using stress-strain diagram and scanning electron micrographs, respectively. The weld joint interface was found to be the weakest zone rather than weld stirred zone due to the presence of carbon reach phases as per micro-hardness variation through the weld centerline along with energy dispersive spectroscopy analysis. The maximum joint efficiency was found to be 23.33% at 700-rpm tool rotation and traverse speed of 30 mm/min using threaded pin in slotted edge–based design.


Friction stir welding Dissimilar joint Thermoplastics Slotted edge design Micro-hardness variation Joint efficiency 



The authors are immensely grateful to Steel Technology Centre, IIT Kharagpur, for carrying out the sample preparation and measurement of weld joint quality characteristics. They also wish to acknowledge the assistance and support provided by the Friction stir welding Laboratory of the Department of Mechanical Engineering, IIT Kharagpur.


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Department of Production Engineering, Veer Surendra Sai University of TechnologySambalpurIndia
  2. 2.Department of Mechanical Engineering, Indian Institute of Technology KharagpurKharagpurIndia
  3. 3.Department of Mechanical EngineeringVeer Surendra Sai University of TechnologySambalpurIndia

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