Analysis of cooling media effects on microstructure and mechanical properties during FSW/UFSW of AA 6082-T6

The aim of the present study is to investigate the effect of cooling media on the temperature distribution, microstructure and mechanical properties of the joint produced during Underwater Friction Stir Welding (UFSW) in normal water, cold water (water with crushed ice (CFSW)) and air (FSW), for aluminum alloy (AA) 6082-T6. The results showed that peak temperature during UFSW and CFSW were significantly lower than the FSW. The temperature at the advancing side (AS) of the joint was higher than the retreating side (RS). Substantial reduction in TMAZ/HAZ width was observed during UFSW and CFSW as compared to FSW. Al-Mn-Fe-Si intermetallic phases were seen in all the joints along with the BM. The main strengthening precipitates found in UFSW and CFSW was ?'' (Mg5Si6) which changed to ? (Mg2Si) precipitates during FSW due to increased temperature. The tensile strength of the joints was best during UFSW followed by FSW and CFSW. The controlled temperature distribution resulted in improved tensile strength whereas both undercooling and overcooling resulted in decreased tensile strength, however, increased cooling rate does not improve the elongation. A typical 'W' shape hardness profile was observed in all the joints irrespective of the cooling media used. Maximum hardness was obtained in the UFSW joint due to refined grain structure, high-density dislocations and presence of ?'' phases.