International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 10 Issue: 07 | July 2023
p-ISSN: 2395-0072
www.irjet.net
Effect of Process Parameters and Nano particles on Friction Stir Welding of Dissimilar Aluminium Alloys: Review K C Mahendra 1, Channaveera Swamy J M 2, Javeed S 3, Pavan Kumar B K 4, Prince Kumar Singh 5, Raghavendra M 6 1 Assistant Professor, Department of Mechanical Engineering, RYM Engineering College, Ballari, Karnataka, India 2 Technical Staff, Department of Mechanical Engineering, RYM Engineering College, Ballari, Karnataka, India 3-6 UG Students, Department of Mechanical Engineering, RYM Engineering College, Ballari, Karnataka, India
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Abstract - Friction stir welding (FSW) is an advanced
in industries such as power generation, chemical, petrochemical, aerospace, transportation, electronics, and military. Examples include aero-engines, aerospace propulsion systems, metal ducting structures, and bimetal components for aerospace instruments.
joining technique used in the industrial sector to connect various materials. It is a solid-state connection technology that utilizes a non-consumable tool to join work piece materials. FSW can be applied to similar and dissimilar materials, including ferrous, nonferrous, and polymers, enabling the development of sustainable products. It finds applications in the automobile and aerospace industries for lightweight designs and enhanced the performance. This paper comprehensively summarizes the most recent literature related to the friction stir welding of dissimilar aluminum alloys with nano-particle addition. The research field of the friction stir welding of aluminum with different alloys is analyzed and investigated from the aspects of welding technology, microstructure and mechanical properties, as well as innovations and improvements in the welding process. In view of the exploration status of this field, the authors put forward their views and prospects for its future, aiming to provide a basis for researchers in this field.
When it comes to welding dissimilar materials, challenges arise due to the differences in their properties and behavior during welding. For instance, welding copper (Cu) and aluminum (Al) presents difficulties because of their significantly different melting points and limited mutual solubility. The formation of intermetallic compounds (IMCs) is common during welding, but thicker IMCs can cause diffusion and continuous thickening, affecting the performance of the joint. Additionally, oxidation and the difference in linear expansion coefficients between Al and Cu can lead to defects like cracks and stress in the welded joint. In summary, while the challenges in metal joining technology are intensifying across industries, advancements in joining methods like friction stir welding have shown promising results in joining light alloys. Simultaneously, the welding of dissimilar materials is gaining importance due to its potential to optimize material advantages and meet diverse industry needs. However, addressing the specific challenges associated with dissimilar material welding, such as the formation of intermetallic compounds and managing differences in properties, remains a focus of research and development in the field.
Key Words: Aluminum alloys; Nano-particles; friction stir welding; Microstructure characteristics; Mechanical properties
1. INTRODUCTION The challenges in metal joining technology are increasing in various industries, as new materials are being introduced and there is a need to develop innovative joining methods while ensuring the quality and strength of the products. One emerging trend in car development is the use of light alloys such as aluminum and magnesium in order to improve the efficiency and economy of automobiles. Friction stir welding (FSW) technology has been implemented in automotive production since 2012, providing satisfactory results in joining aluminum-steel alloys and offering benefits like improved driving characteristics and shorter production time.
1.1 Friction Stir Welding FSW is a solid-state, hot-shear joining process in which a rotating tool with a shoulder moves along the butting surface of two rigidly clamped plates placed on a bucking plate as shown in Fig. 1. It was developed in the early 1990s by The Welding Institute (TWI) in the United Kingdom. FSW is particularly well-suited for joining aluminum and its alloys, although it can also be used for other materials such as copper, titanium, and some steels.
On the other hand, there is growing interest in the welding of dissimilar materials due to the demand for complex parts and the need to maximize the advantages of different materials. Composite parts joined using dissimilar materials can meet various performance requirements while reducing costs. The welding of dissimilar materials is being employed
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The process involves a non-consumable tool, typically made of a hard material like tungsten carbide, which is rotated and plunged into the joint between the two work pieces. The tool generates frictional heat as it rotates,
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