Experimental investigation and Optimization in friction stir welding Of dissimilar aluminium alloys

Abstract

Welding dissimilar alloys of aluminium are quite cumbersome due to their lower melting temperatures and difficulty in welding. To resolve this, solid-state procedure Friction Stir Welding (FSW) is utilized largely in industries. This research is aimed at performing FSW on dissimilar aluminium alloy butt joints with emphasis on tool pin profile and welding parameter influence on the mechanical strength of the weld beads. newlineIn the first study, dissimilar alloys of aluminium AA2014 are joined with AA6061 considering threaded cylinder, tapered cylinder, taper threaded, conical and simple cylindrical tool pin profiles and varying conditions of Tool Rotational Speed (TRS), Tool Traverse Speed (TTS) and Axial Force (AF). Outcomes show that, all the considered input parameters had a significant impact on the output responses. The optimum condition obtained is TRS of 1153 rpm, 16 mm/min as TTS, 7 kN of AF with tapered cylindrical tool pin profile. The output values predicted by the developed model are the yield strength of 140.113 MPa, the ultimate strength of 165.994 MPa, elongation of 4.93%, and microhardness of 92.04 HV. newline