International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 04 Issue: 07 | July -2017
p-ISSN: 2395-0072
www.irjet.net
An Experimental Analysis and Optimization of Process Parameters on Friction Stir Welding of Dissimilar AA6061-T6 and AA6951-T6 Using Taguchi Technique Surjeet Singh1, Kamaljit Singh2, ishavneet Singh3 Charan Shivesh4 1,4Research
Scholar, Mechanical Engg. Dept. BUEST, Baddi, H.P, (India) Professor, Mechanical Engg. Dept. BUEST, Baddi, H.P, (India) ---------------------------------------------------------------------***--------------------------------------------------------------------surface. Heat is generated by the tool shoulder rubbing on Abstract - Aluminum alloys are broadly used in aerospace 2,3Assistant
the surface and by the pin mixing the material below the shoulder. This mixing action permits the material to be transferred across the joint line, allowing a weld to be made without any melting of the material.
industry, automotive industry, railways and in marine industry due to its resistance to corrosion, light weight and high strength to weight ratio. The aim of the present research is to optimize the process parameters for higher tensile strength and to analyze the effect of process parameters such as tool rotational speed, welding speed and tool tilt angle on the tensile strength of friction stir weldments. Taguchi L9 orthogonal array was used to conduct the experiments. The optimum process parameters for the maximum tensile strength of the joints were predicted, and the individual significance of each process parameter on the tensile strength of the friction stir weldment was evaluated by using the signalto-noise ratio and analysis of variance (ANOVA) results.
1.1 Principle of Friction Stir Welding Friction Stir Welding is a solid-state process, which means that the objects are joined before reaching the melting point. In FSW process, a cylindrical-shouldered tool, with a profiled probe (nib or pin) is rotated at a constant speed and fed at a constant traverse rate into the joint line between two pieces of sheet or plate material. The parts to be joined are clamped rigidly in order to prevent the joint faces from being forced apart. The tool pin length is kept slightly less than the weld depth required so that there should be an intimate contact of shoulder with the work surface.
Key Words: Friction Stir Welding, Dissimilar Joining, Rotational Speed, Welding Speed, Tool Tilt Angle, Tensile Strength
1. INTRODUCTION The dissimilar joining of metals with different thermomechanical and chemical properties is often more challenging as it results in the formation of brittle intermetallic compounds. Joining of aluminum (Al) or its alloys with copper (Cu) is preferred in many applications in engineering [1]. In aircraft and automotive structures friction stir welded lap joints have been widely used with the aim to replace riveted lap joints by using aluminium alloys. Rivet holes are often potential sites for crack initiation or corrosion problems; moreover, the elimination of fasteners leads to considerable weight and cost savings. A few examples of FSW joints applied in automotive industries are some applications include engines, wheel rims and lap joints in car back supports Friction Stir Welding (FSW) is a solid welding process invented by The Welding Institute (TWI) in 1991 [2]. In the Friction Stir Welding process, a non-consumable, rotating tool with a specific geometry is plunged into and traversed through the material. The two key components of the tool are the shoulder and the pin (probe). During welding, the pin travels in the material, while the shoulder rubs along the
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Fig -1: Principle of friction stir welding [3] There is a generation of frictional heat between the wearresistant welding tool shoulder and nib, and the material of the work pieces. This generated heat, along with the heat generated by the mechanical mixing process and the
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