Evaluating the Welding Pulses of Various Tool Profiles in Single-Pass Friction Stir Welding of 6082-T6 Aluminium Alloy

Aluminium alloy 6082-T6 plays a vital role in the fabrication of lightweight structures, especially for manufacturing artillery, defense vehicles, and aircraft. is well-known structural having high strength-to-weight ratio favorable corrosion resistance properties extreme environments. In this study, three friction stir welding (FSW) process parameters (spindle speed, weld shoulder penetration), two geometrical tool to precisely describe pin profile, profile were considered at five levels. Optimization was conducted using Taguchi experimental design method, FSW experiments conventional milling machine. The optimized maximize tensile strength various plate thicknesses. number polygon edges determines corresponding pulses. results show that 105-110 pulses/s an optimal value achieve high-quality, defect-free weld. Key words: Friction welding, alloy, Welding pulses, Taguchi, Microstructure