International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 06 | Jun 2025
p-ISSN: 2395-0072
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OPTIMIZATION OF FRICTION STIR WELDING TO ENHANCE MECHANICAL PROPERTIES OF ALUMINUM ALLOY WELDMENTS Niraj Kumar1, Ashish Kumar Srivastava2 1M.Tech. (ME) Scholar, Department of Mechanical Engineering, Goel Institute of Technology and Management
Lucknow, Uttar Pradesh, India
2Assistant Professor, Department of Mechanical Engineering, Goel Institute of Technology and Management
Lucknow, Uttar Pradesh, India
----------------------------------------------------------------------***--------------------------------------------------------------------create materials with a variety of mechanical, chemical, Abstract: Friction Stir Welding (FSW) is an innovative and physical characteristics. The material's solid-state joining technique, especially effective for characteristics, geometric complexity, quantity, and aluminum alloys such as AA6061, widely used in economics all play a role in the manufacturing process aerospace, automotive, and structural applications. This choices. study focuses on the optimization of key FSW process parameters—tool rotational speed, welding speed, and Casting and forming are referred to as zero processes for axial force—to achieve defect-free welds and enhance the component manufacturing. With these methods, no mechanical and microstructural characteristics of the material is added or withdrawn; just the shape of the raw welded joints. The primary objective is to maximize the material is altered. Since material is removed to create mechanical performance of AA6061 welds by identifying components with the proper shape and size, machining is the optimal combination of parameters that minimizes referred to as a negative process. The sole constructive defects and improves strength. method for adding material to create components is welding. According to Misra et al. (2005), welding has A series of experiments were designed using the Taguchi several advantages over other procedures, including method to systematically analyze the influence of each being permanent, having a higher strength than base process variable. The welded joints were evaluated for metal, and being more cost-effective. Even though tensile strength, hardness, and impact strength to welding is thought to be a relatively modern joining understand the correlation between process parameters technique as it is currently used, it was once utilised to and mechanical performance. Furthermore, detailed create tools, weapons, and other ancient equipment microstructural analysis was performed using optical (Iordachescu et al. 2005). microscopy and scanning electron microscopy (SEM) to assess grain refinement, material flow, and defect During the material joining process, industrial robots are formation in different weld zones. employed to automatically control the processes. The welding torch is automatically controlled by a robot that Keywords- Friction Stir Welding (FSW), AA6061 is programmed to follow a predetermined course in the Aluminum Alloy, Process Parameter Optimization, specified orientation. A robot was made up of numerous Mechanical Properties, Microstructural Analysis, Taguchi links and linkages that were connected by power drives. Method etc. All other welding methods are being replaced by industrial robots because of their precision, speed, and 1. INTRODUCTION inventiveness. According to J. F. Lancaster (1999), welding is a joining 1.1. The process of friction stir welding method that creates a permanent bond between two materials through coalescence, which is brought on by a Friction stir welding (FSW) was created in 1991 by the confluence of metallurgical conditions, temperature, and Welding Institute (Thomas et al. 1991). The method is pressure. Certain welding procedures are carried out by based on traditional frictional welding. This method heating them to the welding temperature, either with or works well for flat components and is also appropriate without the use of pressure. Filler metal is also utilised in for hollow sections and pipelines. According to Ma et al. certain welding processes to promote coalescence. (2017), it has become a novel solid-state welding method Although welding is typically thought of in relation to for metal matrix composites as well as aluminium, metal components, it can also be used to join plastics. magnesium, and titanium alloys. These days, plastic and A variety of manufacturing techniques can be used to high-strength steel are joined using this method as well create an engineering component. The operations of (Jafarzadegan et al. 2013). Automobiles, aeroplanes, casting, machining, forming, and welding can be used to
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