Abstract
Friction stir welding has been used in automobiles, locomotive, and aircraft structures. This metal joining process exhibits defects like kissing bonds, micropores, and tunnels. Factors like the joining material, joint thickness, tool geometry, and operating parameters control the defects in friction stir welding. The parameters like tool rotation, tool pass speed, and tool force have a greater influence on the joint quality. In this study, these parameters are considered to augment the strength of the joint and minimize defects. The metal matrix composite consisting of AA6061 matrix and 10 wt. % SiCp reinforcement is joined used FSW. The weld parameters were varied between 731 and 1068 rpm tool rotation speed, 0.33 and 1.17 mm/s tool pass speed, and 11 and 28 MPa tool force. The joint strength varied from 165 MPa to 244 MPa. The numerical analysis using ANOVA revealed that compared between the three parameters, the tool force had greater control over the tensile strength of the joint. After optimization, the joint was made at a tool rotation speed of 910 rpm, tool pass speed of 0.77 mm/s, and tool force of 22.33 MPa. The tensile strength increased to 249 MPa after using the optimized weld parameters. The number of defects in the joint was reduced after using the optimized weld parameters.
Highlights
Ever since its discovery in 1991 by The Welding Institute, UK, the solid-state metal joining process called the FrictionStir Welding (FSW) has gained recognition as a versatile metal joining process [1]
Equation (3) shows the final empirical relationship for the desired tensile strength of the FrictionStir Welding (FSW) joint produced on the Metal Matrix Composite (MMC)
After fixing the tool force as 22.3 MPa, the tensile strength of the FSW joint was sensitive to tool rotation speed and tool pass speed
Summary
Ever since its discovery in 1991 by The Welding Institute, UK, the solid-state metal joining process called the Friction. Optimization of the FSW parameters is carried out on the Metal Matrix Composite (MMC) containing. The parameters are optimized to augment the tensile strength of the FSW joints and reduce the defects in the joint. The optimization was carried out in an attempt to reduce the defects while enhancing the tensile strength in the FSW joint. Optimization of the FSW parameters was carried out to get joints with minimal defects. Equation (1) shows the relationship between the tensile strength of the FSW joint and the three parameters considered for the optimization. Equation (3) shows the final empirical relationship for the desired tensile strength of the FSW joint produced on the MMC
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