Experimental Investigations and Analysis of Friction Stir Welding of Aluminium Alloy

Abstract

This thesis presents a systematic approach to optimizing Friction Stir Welding pro- cess parameters for the aluminium alloy. Friction stir welding (FSW) is widely used for the welding of aluminium alloy. Welding input parameters play a very signi cant role in determining the quality of a weld joint. The welding parameters such as tool shoulder diameter, tool rotational speed, welding speed and axial force play a major role in deciding the joint strength. In present study an attempt have been made to join the AA5083 aluminium alloy by using the conventional milling machine. Non- consumable tool, made of high carbon, high chromium tool steel, H-13 have been used to fabricate the joints. Friction stir welding have been carried out on the 6 mm thick AA5083 plate. Four factors, ve levels central composite design have been used to minimize number of experimental conditions. Total 31 experiments have been car- ried out. The tensile specimen prepared as per the ASTM E8M-04 and tested on the universal tensile testing machine. Response Surface Methodology (RSM) have been used to develop the mathematical model for the tensile strength. The e ect of the di ferent parameters on the tensile strength has been evaluated. The K-type ther- mocouples have been used to measure the temperature at di erent location on the work piece using data acquisition system. Microstructure examination of the welded component heve been carried out. Results of the study indicate that the maximum tensile strength found in the FSW welded joint is 75 % of the parent metal tensile strength. FSW is being successfully applied to the aerospace, automobile, and ship- building industries.