Failure Analysis of Al 6082 Joints Processed by FSW and SFSW

This paper presents a failure analysis of Al 6082 joints processed by Friction Stir Welding (FSW) and Self-Reacting Friction Stir Welding (SFSW) techniques. Aluminium alloy Al 6082 is commonly used in structural and automotive applications due to its excellent strength, corrosion resistance, and weldability. The study focuses on investigating the failures encountered in FSW and SFSW joints of Al 6082. Macroscopic and microscopic examinations are conducted to analyse the root causes of these failures. Macroscopic observations include visual inspection, dimensional measurements, and identification of fracture locations. Microscopic investigations utilize techniques such as optical microscopy, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) to examine the microstructure, fracture surfaces, and elemental composition of the failed joints. The results of this failure analysis contribute to the understanding of Al 6082 joining processes using FSW and SFSW methods. By identifying the failure mechanisms and proposing preventive measures, this research aids in improving the quality and performance of Al 6082 joints, thereby ensuring the integrity and reliability of joined structures in industries that rely on aluminium alloys for critical applications.