Aluminium alloys are widely used in the industry of transportation, such as aerospace and automotive. With the current transformation from ICE power units to EV vehicles in the latest, the need of lightweight materials is increasing. Therefore, this project centres itself in investigating the possibility of using an aluminium alloy, AA6063 T6, to create the battery trays under the passengers in the new EV’s.

To construct a battery tray, butt joints are needed for the base and cover and lap joint to attach both to the walls. This study examines both options with different welding parameters, with the objective of finding the best result for the automotive industry.

In the case of the lap samples, HS-FSW is used to create different samples. Only six of those were deemed in a good state to be examined, defects and mechanical properties, such as hardness and tensile strength.

On the other hand, the butt samples were welded in pairs and analysed following the same procedure as the butt samples. However, this part of the study was not completed and is left as future work.

Concluding the study, a relation between the parameters and the obtained results was obtained, as well as defect free butt welds at high speed. This fulfils the possible needs of the industry, allowing an alternative and increasing productivity with HS-FSW methods.