FSW Tool Profile Effects on Marine Grade Aluminium Weld Integrity

The book studies the influence of tool profile and welding parameters in Friction Stir Welding (FSW) of marine-grade aluminium alloy AA6061. Friction Stir Welding It explains the principles of FSW, different weld zones, marine aluminium alloys, and temperature measurement techniques used during welding. The research compares three tool geometries-tapered cone, tapered three-edge, and tapered four-edge tools-under different spindle speeds and feed rates. Experimental results show that spindle speed strongly affects heat generation, while lower feed rates increase heat accumulation. Among the tested tools, the tapered four-edge tool produced more uniform temperature distribution and better weld integrity. The study concludes that proper optimization of tool geometry and process parameters helps achieve strong, defect-free, and high-quality welds suitable for marine and structural applications.