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Friction stir spot welding is a unique solid-state process for joining different metallic components in many applications such as automotive industry. It is very widely used and being considered as a superior alternative to conventional joining methods. The welding process parameters include the tool rotational speed, pin length, shoulder width and dwell time. Optimum process parameters where identified in prior investigations that produced the highest joint strength for this type pf alloys. This paper is a trial to validate these results and explain the high strength of the welded joint through microstructural investigations. Optical microscopy, scanning electron microscopy and Vicker’s microhardness tests were used to analyze the welded joint. The investigation validated the optimum process conditions in microstructural and hardness variations across the different zones of the welded joint.

Friction Stir Spot Welding – A validation Study for Optimal Welding Parameters of Aluminum Alloy 6061