High speed friction stir welding of AA6063-T6 alloy in lightweight battery trays for EV industry: Influence of tool rotation speeds

Present work demonstrates high speed friction stir welding (HSFSW) of light weight battery trays assembly in electric vehicle (EV). Despite solid-state and green nature FSW, it suffers from the relatively low speed. With help suitable tool design machine parameters, we successfully achieved defect-free welds at 4.0 4.5 m/min. Good quality are produced 3 mm thick AA6063-T6 extruded aluminium alloy such a speeds by implementing violent material mixing i.e., higher rotation (3500–4500 rpm) plunge force (8.5–10.5 kN). The HSFSW cross-section registered curious hardness profile ‘U’ shape. resulted softening weld zone (∼60 HV) along with HAZ (∼50 HV). highest joint efficiency 72 % was found for m/min 3500 rpm.