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Solid-state welding for low-melting point materials is suitable to produce defect-free weld joints. Therefore, in the present work AA 6063 alloy was welded using friction stir welding (FSW) to know the fracture strength of the welded joint along with the microstructural characterisation. The join was made using a tool of cylindrical shape having varied tool shoulder diameter. The qualities of weld joint are evaluated with the existence of weld defects and microstructure, whereas mechanical properties are obtained as tensile strength, bend test and micro-hardness. The hardness of welded samples at the nugget zone is more or less similar for all process parameters and tool shape. Whereas, the bending strength and tensile strength were found to be varied with rotational speed but decrease as a function of transverse speed. The fractured image revealed that the ductility is higher at the lower band angle. Microstructural examination revealed that the grain growth exhibited in the thermo-mechanical affected zone (TMAZ) and heat-affected zone (HAZ).

Microstructure characterisation and mechanical behaviour of AA 6063 T-6 welded joint by friction stir welding