Effects of Rotational Speed on Microstructure and Mechanical Properties of Friction Stir Spot-Welded AA6082-T6/AA1050 Dissimilar Lap Joints
Moahmed, A., Gadallah, E., Elwan, M., Seleman, M., Elshaghoul, Y., El-Fahhar, H. (2025). Effects of Rotational Speed on Microstructure and Mechanical Properties of Friction Stir Spot-Welded AA6082-T6/AA1050 Dissimilar Lap Joints. EKB Journal Management System, 54(2), 95-112. doi: 10.21608/jesaun.2025.395411.1557
abdelkarim Moahmed; Elshafey Ahmed Gadallah; Medhat Elwan; Mohamed M. El-Sayed Seleman; yousef Gamal Elshaghoul; Hossam Hemdan El-Fahhar. "Effects of Rotational Speed on Microstructure and Mechanical Properties of Friction Stir Spot-Welded AA6082-T6/AA1050 Dissimilar Lap Joints". EKB Journal Management System, 54, 2, 2025, 95-112. doi: 10.21608/jesaun.2025.395411.1557
Moahmed, A., Gadallah, E., Elwan, M., Seleman, M., Elshaghoul, Y., El-Fahhar, H. (2025). 'Effects of Rotational Speed on Microstructure and Mechanical Properties of Friction Stir Spot-Welded AA6082-T6/AA1050 Dissimilar Lap Joints', EKB Journal Management System, 54(2), pp. 95-112. doi: 10.21608/jesaun.2025.395411.1557
Moahmed, A., Gadallah, E., Elwan, M., Seleman, M., Elshaghoul, Y., El-Fahhar, H. Effects of Rotational Speed on Microstructure and Mechanical Properties of Friction Stir Spot-Welded AA6082-T6/AA1050 Dissimilar Lap Joints. EKB Journal Management System, 2025; 54(2): 95-112. doi: 10.21608/jesaun.2025.395411.1557

Effects of Rotational Speed on Microstructure and Mechanical Properties of Friction Stir Spot-Welded AA6082-T6/AA1050 Dissimilar Lap Joints

JES. Journal of Engineering Sciences
Article 9, Volume 54, Issue 2, March and April 2026, Pages 95-112    PDF (1.2 M)
Document Type: Research Paper
DOI: 10.21608/jesaun.2025.395411.1557
Authors
abdelkarim Moahmed1; Elshafey Ahmed Gadallah1; Medhat Elwan* 1; Mohamed M. El-Sayed Seleman2; yousef Gamal Elshaghoul3; Hossam Hemdan El-Fahhar1
1Mechanical Production Department, Faculty of Technology & Education, Suez University, Suez 43527, Egypt.
2Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43221, Egypt.
3Department of Mechanical Engineering, Faculty of Engineering, Suez University, Suez P.O. Box 43221, Egypt.
Abstract
In this study, the macrostructure and mechanical characteristics of friction stir spot-welded (FSSWed) dissimilar lap joints between AA6082-T6 and AA1050 were investigated as a function of rotational speed. The FSSW procedure was carried out with a constant dwell time of 4 s and rotating speeds of 500, 700, and 900 rpm. The results showed that the heat input and maximum peak temperature increased by increasing the rotational speed, which improved material flow and wider bonding area between the upper and lower sheets. Microhardness measurements in the stir zone indicated an increase in higher value at lower rotational speeds, increasing from 86.9 HV at 900 rpm to 102.3 HV at 500 rpm, due to enhanced material flow, plastic deformation and re-precipitation of strengthening phases. Tensile-shear tests revealed a non-linear relationship between rotational speed and joint strength, with a maximum load of 4.58 kN at 500 rpm. Fracture analysis showed a shift from ductile fracture at lower speeds to a mix of ductile and smooth fracture features at higher speeds, indicating changes in the failure mechanism.
Keywords
Friction stir spot welding; AA6082-T6; AA1050; Dissimilar lap joints; Mechanical properties
References
  1. Kumar, S.; Jambhale, S.; Maurya, M.; Kumar, S.; Pandey, S. Evaluation of Shear Force and Fractography of Friction Stir Spot Welded Joints of AA 6082-T6 Alloy. Journal of Engineering Research (Kuwait) 2022, 10, 124–144, doi:10.36909/jer.10265.
  2. Ahmed, M.M.Z.; El-Sayed Seleman, M.M.; Ahmed, E.; Reyad, H.A.; Alsaleh, N.A.; Albaijan, I. A Novel Friction Stir Deposition Technique to Refill Keyhole of Friction Stir Spot Welded AA6082-T6 Dissimilar Joints of Different Sheet Thicknesses. Materials 2022, 15, doi:10.3390/ma15196799.
  3. Essa, A.R.S.; Aboud, A.R.K.; Ahmed, M.M.Z.; El-Nikhaily, A.E.; Easa, A.S.; Habba, M.I.A. Friction Stir Welding of Aluminum Alloy 6082-T6 Using Eccentric Shoulder Tools to Eliminate the Need for Tool Tilting. Sci Rep 2025, 15, doi:10.1038/s41598-025-91065-1.
  4. El-Fahhar, H.H.; Gadallah, E.A.; Habba, M.I.A.; Seleman, M.M.E.-S.; Ahmed, M.M.Z.; Mohamed, A.Y.; Fouad, R.A. Effect of Post-Weld Heat-Treatment and Solid-State Thermomechanical Treatment on the Properties of the AA6082 MIG Welded Joints. Sci Rep 2024, 14, doi:10.1038/s41598-024-53795-6.
  5. Ahmed, M.M.Z.; Seleman, M.M.E.S.; Ahmed, E.; Reyad, H.A.; Touileb, K.; Albaijan, I. Friction Stir Spot Welding of Different Thickness Sheets of Aluminum Alloy AA6082-T6. Materials 2022, 15, doi:10.3390/ma15092971.
  6. Alzahrani, B.; Ahmed, M.M.Z.; Habba, M.I.A.; Fouad, R.A.; Elshaghoul, Y.G.Y.; Gadallah, E.A. TIG Welding of EN AW-6082 Al Alloy: A Comparative Analysis of Filler Rods on Microstructural and Mechanical Performance. Journal of Manufacturing and Materials Processing 2025, 9, doi:10.3390/jmmp9010021.
  7. I. A. Habba, M.; Kh. Younis, M.; Sadoun, A.M.; Fathy, A.; Barakat, W.S. On the Microstructural and Mechanical Responses of Dual-Matrix Al-Ni/SiC Composites Manufactured Using Accumulative Roll Bonding. Alexandria Engineering Journal 2023, 78, 1–14, doi: 10.1016/j.aej.2023.07.030.
  8. Elwan, M.; Fathy, A.; Wagih, A.; Essa, A.R.S.; Abu-Oqail, A.; El-Nikhaily, A.E. Fabrication and Investigation on the Properties of Ilmenite (FeTiO3)-Based Al Composite by Accumulative Roll Bonding. J Compos Mater 2020, 54, 1259–1271.
  9. Ahmed, M.M.Z.; El-Sayed Seleman, M.M.; Eid, R.G.; Zawrah, M.F. Production of AA1050/Silica Fume Composite by Bobbin Tool-Friction Stir Processing: Microstructure, Composition and Mechanical Properties. CIRP J Manuf Sci Technol 2022, 38, 801–812, doi: 10.1016/J.CIRPJ.2022.07.002.
  10. Barakat, W.S.; Kh. Younis, M.; Sadoun, A.M.; Fathy, A.; Habba, M.I.A. Optimization of the Accumulative Roll Bonding Process Parameters and SiC Content for Optimum Enhancement in Mechanical Properties of Al-Ni-SiC Composites. Alexandria Engineering Journal 2023, 76, 131–151, doi: 10.1016/j.aej.2023.06.027.
  11. Aydin, H.; Tuncel, O.; Umur, Y.; Tutar, M.; Bayram, A. Effect of Welding Parameters on Microstructure and Mechanical Properties of Aluminum Alloy AA6082-T6 Friction Stir Spot Welds; 2017; Vol. 24;.
  12. Elshaghoul, Y.G.Y.; El-Sayed Seleman, M.M.; Bakkar, A.; Elnekhaily, S.A.; Albaijan, I.; Ahmed, M.M.Z.; Abdel-Samad, A.; Reda, R. Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts. Applied Sciences (Switzerland) 2023, 13, doi:10.3390/app131810255.
  13. Habba, M.I.A.; Ahmed, M.M.Z. Friction Stir Welding of Dissimilar Aluminum and Copper Alloys: A Review of Strategies for Enhancing Joint Quality. Journal of Advanced Joining Processes 2025, 11, doi: 10.1016/j.jajp.2025.100293.
  14. Habba, M.I.A.; Ahmed, M.M.Z. Friction Stir Welding-Based Technologies: A Comprehensive Review from the Sustainable Manufacturing Perspectives. Journal of Materials Research and Technology 2025, 38, 1–29, doi: 10.1016/J.JMRT.2025.07.184.
  15. Sadoun, A.M.; Wagih, A.; Fathy, A.; Essa, A.R.S. Effect of Tool Pin Side Area Ratio on Temperature Distribution in Friction Stir Welding. Results Phys 2019, 15, doi: 10.1016/j.rinp.2019.102814.
  16. Ahmed, M.M.Z.; El-Sayed Seleman, M.M.; Albaijan, I.; Abd El-Aty, A. Microstructure, Texture, and Mechanical Properties of Friction Stir Spot-Welded AA5052-H32: Influence of Tool Rotation Rate. Materials 2023, 16, doi:10.3390/ma16093423.
  17. Rabea, M.F.; Fouad, R.A.; El-Sayed Seleman, M.M.; Ahmed, E. Effect of Dwell Time on Mechanical and Metallurgical Behavior of Dissimilar FSSWed Cu-S355 JR Lap Joints. The International Journal of Advanced Manufacturing Technology 2025, 138, 873–894, doi:10.1007/s00170-025-15565-0.
  18. Ikuta, A.; Yin, Y.H.; North, T.H. Influence of Tool Thread on Mechanical Properties of Dissimilar Al Alloy Friction Stir Spot Welds. Science and Technology of Welding and Joining 2012, 17, 622–629, doi:10.1179/1362171812Y.0000000053.
  19. Abbass, M.K.; Hussein, S.K.; Khudhair, A.A. Optimization of Mechanical Properties of Friction Stir Spot Welded Joints for Dissimilar Aluminum Alloys (AA2024-T3 and AA 5754-H114). Arab J Sci Eng 2016, 41, 4563–4572, doi:10.1007/s13369-016-2172-9.
  20. Khosa, S.U.; Weinberger, T.; Enzinger, N. Thermo-Mechanical Investigations during Friction Stir Spot Welding (FSSW) of AA6082-T6. Welding in the World 2010, 54, R134–R146, doi:10.1007/BF03263499.
  21. Ouis, A.; Habba, M.I.A.; Ahmed, M.M.Z.; Barakat, W.S. Tribological and Corrosion Behavior of Al2O3 Interlayer Reinforced Friction Stir Welded AA6082-T6 Joints. Sci Rep 2025, 15, 22437, doi:10.1038/s41598-025-03977-7.
  22. Sadoun, A.M.; Meselhy, A.F.; Deabs, A.W. Improved Strength and Ductility of Friction Stir Tailor-Welded Blanks of Base Metal AA2024 Reinforced with Interlayer Strip of AA7075. Results Phys 2020, 16, doi: 10.1016/j.rinp.2019.102911.
  23. Habba, M.I.A.; Ahmed, M.M.Z.; Fouad, R.A.; Barakat, W.S. Friction Stir Welding of AA6082-T6 Assisted with a Novel Encapsulated Alumina Interlayer: Surface Morphology, Tribology, and Topographic Analysis. The International Journal of Advanced Manufacturing Technology 2025, 139, 2823–2845, doi:10.1007/s00170-025-16063-z.
  24. Mabuwa, S.; Msomi, V. The Effect of Friction Stir Processing on the Friction Stir Welded AA1050-H14 and AA6082-T6 Joints. Mater Today Proc 2020, 26, 193–199.
  25. Zhang, Z.K.; Yu, Y.; Zhang, J.F.; Wang, X.J. Corrosion Behavior of Keyhole-Free Friction Stir Spot Welded Joints of Dissimilar 6082 Aluminum Alloy and DP600 Galvanized Steel in 3.5% NaCl Solution. Metals (Basel) 2017, 7, doi:10.3390/met7090338.
  26. Ahmed, M.M.Z.; Hajlaoui, K.; Seleman, M.M.E.-S.; Elkady, M.F.; Ataya, S.; Latief, F.H.; Habba, M.I.A. Microstructure and Mechanical Properties of Friction Stir Welded 2205 Duplex Stainless Steel Butt Joints. Materials 2021, 14, doi:10.3390/ma14216640.
  27. Habba, M.I.A.; Alsaleh, N.A.; Badran, T.E.; El-Sayed Seleman, M.M.; Ataya, S.; El-Nikhaily, A.E.; Abdul-Latif, A.; Ahmed, M.M.Z. Comparative Study of FSW, MIG, and TIG Welding of AA5083-H111 Based on the Evaluation of Welded Joints and Economic Aspect. Materials 2023, 16, doi:10.3390/ma16145124.
  28. Ahmed, M.S.I.; Ahmed, M.M.Z.; Abd El-Aziz, H.M.; Habba, M.I.A.; Ismael, A.F.; El-Sayed Seleman, M.M.; Abd El-Aty, A.; Alamry, A.; Alzahrani, B.; Touileb, K.; et al. Cladding of Carbon Steel with Stainless Steel Using Friction Stir Welding: Effect of Process Parameters on Microstructure and Mechanical Properties. Crystals (Basel) 2023, 13, doi:10.3390/cryst13111559.
  29. Essa, A.R.S.; Ahmed, M.M.Z.; Mohamed, A.-K.Y.A.; El-Nikhaily, A.E. An Analytical Model of Heat Generation for Eccentric Cylindrical Pin in Friction Stir Welding. Journal of Materials Research and Technology 2016, 5, 234 – 240, doi: 10.1016/j.jmrt.2015.11.009.
  30. Gadakh, V.S.; Adepu, K. Heat Generation Model for Taper Cylindrical Pin Profile in FSW. Journal of Materials Research and Technology 2013, 2, 370–375, doi: 10.1016/j.jmrt.2013.10.003.
  31. Wiedenhoft, A.G.; Amorim, H.J. de; Rosendo, T. de S.; Tier, M.A.D.; Reguly, A. Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints. Materials Research 2018, 21, e20170983.
  32. Ahmed, M.M.Z.; Ataya, S.; El-Sayed Seleman, M.M.; Mahdy, A.M.A.; Alsaleh, N.A.; Ahmed, E. Heat Input and Mechanical Properties Investigation of Friction Stir Welded Aa5083/Aa5754 and Aa5083/Aa7020. Metals (Basel) 2020, 11, 68.
  33. Essa, A.R.S.; Eldersy, R.I.A.; Ahmed, M.M.Z.; Abd El-Aty, A.; Alamry, A.; Alzahrani, B.; El-Nikhaily, A.E.; Habba, M.I.A. Modeling and Experimental Investigation of the Impact of the Hemispherical Tool on Heat Generation and Tensile Properties of Dissimilar Friction Stir Welded AA5083 and AA7075 Al Alloys. Materials 2024, 17, doi:10.3390/ma17020433.
  34. Atak, A.; Sik, A.; Ozdemir, V. Thermo-Mechanical Modeling of Friction Stir Spot Welding and Numerical Solution with the Finite Element Method. International Journal of Engineering and Applied Sciences 2018, 5, 257275.
  35. Ataya, S.; Ahmed, M.M.Z.; El-Sayed Seleman, M.M.; Hajlaoui, K.; Latief, F.H.; Soliman, A.M.; Elshaghoul, Y.G.Y.; Habba, M.I.A. Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints. Materials 2022, 15, 1394.
  36. Tamadon, A.; Pons, D.J.; Sued, K.; Clucas, D. Thermomechanical Grain Refinement in AA6082-T6 Thin Plates under Bobbin Friction Stir Welding. Metals (Basel) 2018, 8, 375.
  37. Patel, V. V.; Sejani, D.J.; Patel, N.J.; Vora, J.J.; Gadhvi, B.J.; Padodara, N.R.; Vamja, C.D. Effect of Tool Rotation Speed on Friction Stir Spot Welded AA5052-H32 and AA6082-T6 Dissimilar Aluminum Alloys. Metallography, Microstructure, and Analysis 2016, 5, 142–148, doi:10.1007/S13632-016-0264-2.
  38. Ahmed, M.M.Z.; Habba, M.I.A.; Jouini, N.; Alzahrani, B.; El-Sayed Seleman, M.M.; El-Nikhaily, A. Bobbin Tool Friction Stir Welding of Aluminum Using Different Tool Pin Geometries: Mathematical Models for the Heat Generation. Metals (Basel) 2021, 11, 1–19, doi:10.3390/met11030438.
  39. Ahmed, M.M.Z.; El-Sayed Seleman, M.M.; Sobih, A.M.E.S.; Bakkar, A.; Albaijan, I.; Touileb, K.; Abd El-Aty, A. Friction Stir-Spot Welding of AA5052-H32 Alloy Sheets: Effects of Dwell Time on Mechanical Properties and Microstructural Evolution. Materials 2023, 16, doi:10.3390/ma16072818.
  40. Koumoulos, E.P.; Charitidis, C.A.; Daniolos, N.M.; Pantelis, D.I. Nanomechanical Properties of Friction Stir Welded AA6082-T6 Aluminum Alloy. Materials Science and Engineering: B 2011, 176, 1585–1589, doi: 10.1016/J.MSEB.2011.01.015.
  41. Arif, W.; Ilman, M.N.; Iswanto, P.T.; Kusmono; Akhyar The Effect of Tool Rotation Speed on Hardness, Tensile Strength, and Microstructure of Dissimilar Friction Stir Welding of Dissimilar AA5083 and AA6061-T6 Alloys. Key Eng Mater 2021, 892, 159–168, doi: 10.4028/WWW.SCIENTIFIC.NET/KEM.892.159.
  42. Tamadon, A.; Pons, D.J.; Clucas, D.; Sued, K. Internal Material Flow Layers in AA6082-T6 Butt-Joints during Bobbin Friction Stir Welding. Metals (Basel) 2019, 9, doi:10.3390/MET9101059.
  43. Moreira, P.M.G.P.; Santos, T.; Tavares, S.M.O.; Richter-Trummer, V.; Vilaça, P.; de Castro, P.M.S.T. Mechanical and Metallurgical Characterization of Friction Stir Welding Joints of AA6061-T6 with AA6082-T6. Mater Des 2009, 30, 180–187, doi: 10.1016/J.MATDES.2008.04.042.
 

Statistics
Article View: 482
PDF Download: 480