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The response surface analysis method was used to systematically study the effect of various parameters on the tensile strength of 6082 aluminum alloy friction plug welding (FPW) joints in this work. The fluidity of the joint and microstructure were observed with a metallurgical microscope. Combined with the temperature field and force analysis, the reason why the root of the joint appears as a weak zone was explained. The results showed that the degree of influence on the tensile strength of FPW joints was rotational speed &gt; upsetting speed &gt; welding time. The optimal FPW joint was obtained when the rotational speed was 2254 rpm, the upsetting speed was 2 mm/s, and the welding time was 25 s, so the tensile strength could reach 262.34 MPa. The microstructure of the FPW joint appeared heterogeneous. According to the different plastic metal fluidities of the joint, it could be divided into four areas. The interaction force at the friction interface was not strong at the root of the FPW joint, so the root often becomes the weak area of the FPW joint.

Process Optimization and Formation Analysis of Friction Plug Welding of 6082 Aluminum Alloy