Analyzing Defects in One-Step Double-Acting Friction Stir Welded of Hollow Aluminum Panel: Influence of Travel Speed

¹ Mechanical Engineering Department, Faculty of Engineering, Universitas Sebelas Maret, Surakarta, Indonesia, 57126
² Research Center for Process and Manufacturing Industry Technology, National Research and Innovation Agency (BRIN), Tangerang Selatan, Indonesia, 15314

^* Corresponding author: nurulmuhayat@staff.uns.ac.id

Abstract

This study investigates hollow aluminum panels AA6061 produced through extrusion. The One-Step Double-Acting Friction Stir Welding (ODFSW) technique was used to weld the panels. The tool rotated at 1500 RPM, and the travel speeds were 15 and 30 mm/min. ODFSW is a friction stir welding process that uses two tools moving simultaneously on the top and bottom surfaces of the workpiece. This method offers an environmentally friendly alternative to conventional fusion welding, which requires more energy and generates higher greenhouse gas emissions. The research aims to evaluate the influence of travel speed on weld defects in ODFSW joints, including flash, surface surface grooves, and surface roughness. The results show that while higher travel speeds can improve weld quality. It also poses challenges in heat management and material mixing, leading to larger defects on the bottom side due to uneven heat distribution. At a travel speed of 15 mm/min, defects such as long flash, significant surface surface grooves, high surface roughness, and exit holes were observed, mainly due to excessive welding temperatures and extended contact times. In contrast, at 30 mm/min, although surface surface grooves on the top side were reduced, defects on the bottom side increased, along with higher surface roughness.