Ultra-thin friction stir welding on Aluminum alloy

Mrunal Panchal, Devax Patel, Hardik Vyas, Kush Mehta

Research output: Contribution to journalConference articleScientificpeer-review


Ultra-thin sheets’ welding is an intricate process either by conventional or advanced techniques. In the present investigation, Micro friction stir welding (FSW) was successfully performed to join the ultrathin (0.5 mm thick) commercial aluminum. Suitable fixture and tool were developed for the ultra-thin sheets to perform experiments. Velocity ratio of rotational speed to transvers speed was varied to obtain ultra-thin friction stir welding. The welded samples were investigated by visual examination, macrographs, microstructure, tensile testing with fracture surface analysis and micro hardness distribution. The results revealed that, the sound joint was achieved at the velocity ratio of 13.71. The tensile strength of 100.877 N/mm2 and elongation of 23.12% were obtained, which were 90.77% and 51.377% of the parent material respectively. Fracture surfaces after tensile testing was observed with elongated dimples indicating
ductile fracture. The maximum micro hardness of 94 HV was observed in the weld zone.
Original languageEnglish
Pages (from-to)2888-2894
Number of pages7
JournalMaterials Today: Proceedings
Publication statusE-pub ahead of print - 19 Mar 2020
MoE publication typeA4 Article in a conference publication
EventInternational Conference of Materials Processing and Characterization - Mathura, India
Duration: 21 Feb 202023 Feb 2020
Conference number: 10


  • Aluminum alloy
  • Mechanical properties
  • Micro friction stir welding
  • Microstructure
  • Ultra-thin

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