Friction stir welding of T-joints: Experimental and statistical analysis

Ibrahim Sabry, Ahmed M. El-Kassas, Abdel Hamid I. Mourad, Dinu Thomas Thekkuden, Jaber Abu Qudeiri

Research output: Contribution to journalArticlepeer-review

35 Citations (Scopus)


T-welded joints are commonly seen in various industrial assemblies. An effort is made to check the applicability of friction stir welding for producing T-joints made of AA6063-T6 using a developed fixture. Quality T-joints were produced free from any surface defects. The effects of three parameters, such as the speed of rotation of the tool, axial force, and travel speed were analyzed. Correspondingly, mechanical characteristics such as tensile strength, hardness in three zones (thermal heat affected zone, heat affected zone, and nugget zone) and temperature distribution were measured. The full factorial analysis was performed with various combinations of parameters generated using factorial design and responses. Evident changes in the strength, hardness, and temperature profile were noticed for each combination of parameters. The three main parameters were significant in every response with p-values less than 0.05, indicating their importance in the friction stir welding process. Mathematical models developed for investigated responses were satisfactory with high R-sq and least percentage error.

Original languageEnglish
Article number38
JournalJournal of Manufacturing and Materials Processing
Issue number2
Publication statusPublished - Jun 2019


  • Friction stir welding (FSW)
  • Full factorial analysis
  • Mechanical characteristics
  • T-joint
  • Temperature

ASJC Scopus subject areas

  • Mechanics of Materials
  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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