Experimental Investigation of Friction stir Welding Using Hybrid Alloys

Abstract

Friction stir welding is an emerging solid state joining process which is used to join metals and alloys having low weldability. In this research work experimental analysis has been performed on FSW for AA 6061 and MgZ31B A. Effect of FSW parameters like tool rpm, tool transverse speed and tool pin profile are investigated. A vertical milling head is used to produce FSW joints. Hot work tool steel (H13) is used as a tool material and total 3 number of tools are manufactured namely as cylindrical pin, tapered pin and square pin. Tool transverse feed of 10, 15 and 20 mm/min and tool rotational speed of 800, 1000 and 1200 rpm are taken for the study. A full factorial method is used for three numbers of parameters and their three levels and total 27 numbers of experiments are conducted keeping all other parameters constant. As a response weld tensile strength of joints are tested according to ASME-IX. Response surface method (RSM) and Analysis of variance (ANOVA) is adopted for the statistical analysis. Chi square method is used for the validation purpose and a strong match has been found between predicted and actual value of weld tensile strength of joints. As a conclusion it has been derived that feed of 15 mm/min, tool rotational speed of 1200 rpm and tapered pin profile gives better weld strength for the given experimental conditions. Furthermore research can be carried out on Bobbin type tool, numerical analysis and multi pass of FSW tool.