Abstract
Development of the Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminium joints, in a faster and reliable manner. This paper presents a systematic approach to develop a mathematical model for predicting the Ultimate Tensile Strength (UTS) of dissimilar aluminum alloy (AA6351 T6 - AA5083 H111) joints by incorporating the Friction Stir Welding (FSW) process parameter such as tool pin profile, tool rotational speed, welding speed, and axial force. The experiment was conducted based on four factors five level central composite rotatable deign with full replication technique. The Response Surface Method (RSM) was employed to develop the model. The developed model was validated using the statistical tool analysis of variance (ANOVA). Conformity tests were carried out to check the accuracy of the developed model. The effects of the FSW process parameters on ultimate tensile strength of friction welded dissimilar joints were discussed in detail. DOI: http://dx.doi.org/10.5755/j01.mech.18.5.2699
Highlights
Friction stir welding (FSW) is a solid state welding process developed by The Welding Institute (UK) in 1991, and being used increasingly for joining aluminium alloys for which fusion welding is often difficult
Five different tools made of High Carbon High Chromium steel (HCHCr) having different pin profile of Straight Square (SS), Tapered Square (TS), Straight Hexagon (SH), Straight Octagon (SO) and Tapered Octagon (TO) without draft were used to weld the Friction Stir Welding (FSW) joints
Ultimate tensile strength, of the joints is a function of tool pin profile, tool rotational speed, welding speed, and axial force and it can be expressed as ut = Y = f (P, N, S, F) MPa where P is function of tool pin profile (Fig. 1); N is rotational speed, rpm; S is welding speed, mm/min; F is axial force, kN
Summary
Since the material subjected to FSW does not melt and recast, the resultant weld offers advantages over conventional fusion welds such as less distortion, lower residual stresses and fewer weld defects[13]. By developing such technology, one of the most important facts is represented by the possibility of joining different aluminium alloys [4]. The present research work focuses on the development of mathematical models to predict the ultimate tensile strength of dissimilar FSW joints of aluminium alloys AA6351-T6 and AA5083-H111. The effects of various process parameters, viz. tool pin profile, tool rotational speed, welding speed, and tool axial force on ultimate tensile strength of dissimilar FSW joints are predicted using the developed models
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