Abstract
Friction stir welding is a solid state technique in which welded joints are performed using non-consumable tool to heat the metal to plasticized state. The tool exerts high friction and sustained stirring over the metal substrate resulting in a sound weld. In the present work, influence of various process parameters on dissimilar welding of AA 6061 T6 and AA7075 T651aluminium alloys is investigated to enhance the strength properties. Cylindrical and Conical tool pin geometries are chosen to prepare butt welded joints. The tool geometry, rotational spindle speed and feed rate are the various process variables considered for the study. The ultimate tensile strength (UTS) and elongation for six welded joints are determined with rotational spindle speed of about 600, 800, 1000 RPM and feed rate of about 30, 45, 60 mm/min respectively. Irrespective of the process parameters, it is observed that, cylindrical tool rendered the better tensile and elongation property compared to the conical tool. Transient Finite Element Analysis is employed for non-linear problem in the Coupled Eulerian-Lagrangian Formulation. The parametric model with base weld plates and the tool is performed using ABAQUS software. Experimental strength results were validated with Finite Element Analysis. The corresponding strain, deformation and nodal temperature values were determined.
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