Mostoftheinvestigationsregardingfrictionstirwelding(FSW)ofaluminumalloyplateshavebeenlimitedtoabout5to6mmthickplates.InpriorworkconductedthevariousaspectsconcerningtheprocessparametersandtheFSWtoolgeometrywerestudiedutilizingfrictionstirweldingof12mmthickcommercialgradealuminumalloy.Twodifferentsimple-tomanufacturetoolgeometrieswereused.TheeffectofvaryingweldingparametersanddwelltimeofFSWtoolonmechanicalpropertiesandweldqualitywasexamined.Itwasobservedthatinordertoachieveadefectfreeweldingonsuchthickaluminumalloyplates,toolhavingtrapezoidalpingeometrywassuitable.Adequatetensilestrengthandductilitycanbeachievedutilizingacombinationofhightoolrotationalspeedofabout2000r/minandlowspeedofweldingaround28mm/min.Atverylowandhighdwelltimetheductilityofweldedjointsarereducedsignificantly.
