This study investigates the influence of tool shapes on tensile properties and microstructural features at stirred zone (SZ) and heat-affected zone of Al 6061 joints welded through friction stir welding (FSW) technique. Six novel dual-pin FSW tools were designed and fabricated consisting of two eccentric pins with different shapes of circle–circle, triangle–triangle (TT), rectangle–rectangle, and the combined pins of circle–triangle, circle–rectangle, and triangle–rectangle. Quasi-static tests were conducted on the welded joint samples and stress–strain data were collected. Dual-pin welding tools led to microstructural evolution including growth in the plastic flow and enlargement in SZ. Weld joints fabricated by TT and rectangle-triangle (RT) tools possessed the maximum values of tensile strength and ductility.

本研究调查了工具形状对通过搅拌摩擦焊 (FSW) 技术焊接的 Al 6061 接头的搅拌区 (SZ) 和热影响区的拉伸性能和微观结构特征的影响。设计并制造了六种新型双销 FSW 工具，包括两个不同形状的圆-圆、三角形-三角形 (TT)、矩形-矩形的偏心销，以及圆-三角形、圆-矩形和三角形的组合销-矩形。对焊接接头样品进行准静态试验并收集应力-应变数据。双销焊接工具导致微观结构演变，包括塑性流动的增长和 SZ 的扩大。由 TT 和矩形-三角形 (RT) 工具制造的焊接接头具有最大的抗拉强度和延展性。