Critical investigation on temperature distribution and power consumption on friction stir welding process

Abstract

Friction Stir Welding (FSW) is an eco-friendly solid-state fusion process that can be used to join two similar or dissimilar (different) materials which require strenuous effort to join by conventional welding processes. Friction Stir Welding (FSW) plays a vital role over conventional welding processes due to no hazardous fumes, less wastage, and lower power consumption. Due to its superiority, FSW can be used across manufacturing/ fabrication industries like automotive, shipbuilding, aerospace, electrical appliances, and so on. In this investigational study, the focus has been given to FSW joint for different materials (AA6061-T6 with CuB370). The objectives of this study are - a) to explore the feasibility of FSW on AA6061-T6 and CuB370 using ‘Full Factorial’ Design of experiment (DOE), b) to examine the power consumed during the process of FSW (AA6061-T6 and CuB370) and the influence of process variables on the power consumption, c) to investigate the effect of process parameters on the temperature distribution of the FSW butt joint between AA 6061-T6 and CuB370. From this study, it can be concluded that the power consumption is minimum with the reduction in weld speed and increment in rotational speed. Under this experimental analysis, the maximum temperature attained during the process is directly related to the welding input variables (weld speed, rotation speed).