Abstract

Aluminum metal matrix composites have been widely used in aerospace industries. It is very tough to join the composite by traditional joining processes because of their special combination of properties such as low weight to strength ratio, greater hardness, their abrasive behavior, high stress generation and large heat affected zone (HAZ) developed. Therefore, non-traditional welding technique provides the effective solutions to these problems. FSW is a non-traditional welding process. It is more efficient as well as an economical welding process which produces very less defects as compared to the other liquid state welding techniques. High weld quality can be obtained by this technique. The main purpose of this work is to prepare AA7075/10%SiC composite using friction stir casting. Characterization was carried out through Scanning Electron Microscopy (SEM), Energy Dispersive X-Ray Analysis (EDAX), X-ray diffraction (XRD) and thermal analyses. The SEM analysis shows quite a uniform distribution of the SiC reinforcing particles with base alloy. EDAX analysis confirmed that elements like Mg, Si, Zn and Cu were present in major quantities. The XRD model of the cast composites confirmed the presence of 7075 base alloy and other base alloy components. The presence of the SiC hard phase component is confirmed at each peak. Thermal analysis showed the evidence of no material loss in the composite materials. Experimentation was conducted with four FSW process variables like tool rotational speed (TRS), welding speed (WS), axial force (AF) and tool geometry. Each parameter has three levels. The process parameter's levels were selected by pilot experiments. Orthogonal array L27 was used for welding experiment. Two responses named tensile strength and hardness were analyzed. A combination of orthogonal arrays as well as experimental designs was used to provide optimal welding process parameters that give the best response. The most optimum process variables were WS, TRS and AF, which influenced the welding performance. The maximum obtained tensile strength and hardness of a developed weld joint were 307.48MPa and123.736 HV respectively.

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