Characterization of Mechanical Properties of Aluminum (AA6061-T6) By Friction Welding E.Ravikumar, N.Arunkumar, and Sunnapu Gunhie Samhit Abstract---The main objective of this investigation was to apply friction welding (FW) for joining of 24mm dia of Aluminum rod AA6061-T6. In the present study an experimental friction welding setup, in which continuous drive friction welding used. At first optimum parameters were obtained to join parts having equal diameter (24mm). In the second part of the study, the effect of welding parameters on welding strengths was investigated. Later the mechanical properties of joints were examined by using tensile test and hardness test, macro & micro analysis. Finally the results obtained were compared and discussed. Keywords-- Aluminum alloy, Friction welding, Mechanical properties, Heat affected zone. I. INTRODUCTION RICTION welding is a solid state welding technique which is being used in recent times to weld similar as well as dissimilar metals so that a defect free weld can be obtained. Many combinations like Low carbon to Stainless steel, Austenitic to Ferrite Stainless Steel, Aluminum to Copper and Titanium to Aluminum or steel have been tried out by various solid state welding processes with reasonably good results. 6061 Aluminum alloys are widely used for structural & marine applications. They have the advantage of being light while at the same time exhibiting good tensile strength. II. LITERATURE REVIEW Mumim Sahin [1] has welded a variety of combinations of materials. Equal and unequal diameters of austenitic stainless steel have been studied and their tensile properties and hardness variation have been researched upon . [2] H.Khalid Rafi, G.D.Janaki Ram, G.Phanikumar, K.Prasad Rao have used Taguchi techniques to determine the optimum friction welding parameters to weld similar 7075 joints.[3] Mumim Sahin, Int .J. Adv Manuf Technol Aluminum has been joined to Copper with reasonable good strength and the presence of intermetallic phases has been established here.[4] E.Ravi Kumar is with the Mechanical & Production Department, Sathyabama University, Chennai, Tamil Nadu, INDIA. (ramakrishnar2009@gmail.com). N.Arun Kumar is with the Mechanical Department, St.Josephs College Of Engineering, Chennai, Tamil Nadu, INDIA (n.arunkumar@rediff mail.com). S.Gunhie Samhit is student of Mechanical & Production Department, B.E., Sathyabama University. Chennai, Tamil Nadu, INDIA (samhit389@gmail.com) Most of the works on Aluminum 6061 alloy concerns with friction stir welding. Jiahu Ouyang, Eswar Yarrapareddy, Radovan Kovacevic, have studied friction stir welding of Al 6061 to Copper and have noticed the formation of Cu Al, CuAl2 and other similar intermetallic phases. [5] In a study by G.Liu, L.E.Murr, C.S.Niou, J.C.McClure, and F.R.Vega, The friction-stir weld zone in 6061-T6 aluminum seems to be characterized by what appears to be a dynamic continuous recrystallization microstructure. Second-phase particles in the work piece are essentially “stirred” into the weld zone where the residual hardness varies from 55 H.V. at the vicinity of the top zone & 65H.V, few m.m. from the bottom. In contrast the work piece hardness which varies between 85 H.V. and 100 H.V. [6] Micro structural characteristics and Mechanical properties of Alumina- 6061 alloy were studied by M.N.Ahmed Fauzi , M.B.Uday, H.Zuhailawati, A.B.Ismail. The study of the interface of ceramic/metal alloy friction welded components has been studied for understanding the quality of bonding between two dissimilar materials. Optical, electron microscopy as well as four-point bending strength and micro hardness measurements have been used to evaluate the quality of bonding of alumina and 6061 aluminum alloy joints produced by friction welding. [7]Dissimilar welding of 6061-T6 alloy with 1018 steel has also been reported by Emel Taban, Jerry E.Gould, John C.Lippold.[8]Takeshi Investigated the influenced of welding parameters on tensile properties of friction welded joints by similar materials of spheroidal graphite iron casting and gray iron casting. [9] The quality and the strength of the weld depend on the correct choice of these parameters. For example Ozdemir has joined AISI340 Laustenitic stainless steel and AISI4340 steel by friction welding using different rotational speed in these studies. He found that the tensile strength of joints was markedly affected by joining rotational and speed selected Ozdemir.N [10]. Ozdemir.N, Sarsilmaz.F, Hascalik.A, have also studied the effect of rotational speed on the interface properties of friction welded of different kind of steel. They observed that the width of the full plastic deformed zone (FPDZ) has an import taunt effect on the strength of friction welded samples and the strength increases with increase of the rotational speed. III. EXPERIMENTAL WORK A. Description of friction welding machine The friction welding machine “FWG 20/300-S” is a machine capable of operating with high precision and with excellent repeatability of all weld parameters. The spindle is F 3rd International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2013) April 29-30, 2013 Singapore 127