Boulevard for Effective Consumption of Power and Energy in Friction Stir Welding

Abstract

Abstract The research work performed using AA7204-5022 material is to create a welding pathway for Friction Stir Welding process with low energy and power utilization along with good quality welds. The mentioned objective has been obtained by varying the welding parameters as welding speed and spindle speed. From this study, it has been recorded that the energy and power utilization can be precised by varying the temperature in the work piece as well as in the weld roots. By analyzing the power available in the mechanical process and also in the external source, the energy and power utilization analysis has been performed. An additional procedure handled for the judgment of good quality welding is the tensile test by analyzing the failures in the weld cross section. With the help of the results obtained during the respective welding operations a pathway for the low energy and power consumption with the high weld quality has been obtained. The result portrays that spindle speed and weld speed plays a significant role in energy and power consumption. At lowest spindle and weld speed, the power utilization is minimized, whereas the energy utilization is reduced at higher spindle speed. Hence it has been found that the minimized power and energy utilization steering at opposite direction in the map of welding parameters. Power consumption augments at both higher weld and spindle speed; meanwhile the significant governing factor for energy utilization is the weld speed. Hence at increased weld speed, the energy consumption could be decreased leading to reduced cost and also increased productivity. Spindle speed and partial penetration restricts the minimization of energy utilization at higher weld speed. But the major thing needed is the high quality welding.. For this purpose increasing the welding speed is the only way to obtain good quality welding