Abstract
A study of dissimilar friction stir welding of two aerospace aluminum alloys AA2219-T87 and AA7075-T73 is carried out with five friction stir welding (FSW) parameters namely rotational speed, welding speed, tool profile, tilt angle and position of material. The welding was performed as per the L16 Orthogonal array formed by Taguchi mixed factorial design matrix. Taguchi and Grey Relational Analysis was used for single and multiple response optimizations respectively for optimizing tensile strength, yield strength and percentage elongation. Tensile testing was carried out and analysis was done for getting the optimum setting parameters level. Then the results for L16 was ranked and the optimized parameter set was predicted to be A1B1C2D1E1. Further experimental validation weld was performed and the results correlate with the predicted value. A joint efficiency of 71.8% which is even higher than the predicted values was obtained. Microstructural and hardness studies were performed on the validated welds. Fractography was done to understand the mode of failure occurs in the weld region and most fracture occurs with an offset towards AA2219 side. The presence of intermetallic is found in EDS analysis and XRD further validates the intermetallic composition.
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