Abstract
Friction stir welding (FSW) is a recent novel joining mechanism in the solid-state welding process. It is extensively used to join similar and dissimilar materials as well. This research studied and found the optimum process parameters of FSW based on the temperature simulation results on a 5-mm 6061 Al alloy sheet with a butt joint configuration. Steady-state heat transfer analysis was performed using a transient thermal workbench to predict and identify the optimum parameters based on the simulation welding temperature result. The parameters are optimized using the hybrid Taguchi L9 orthogonal array and grey relation analysis (GRA) method with a larger is better quality characteristic. The mechanical properties of the weld joints such as hardness and tensile strength were studied at an ambient temperature. The result revealed that a higher rotational and minimum welding speed with taper threaded tool pin imparts the optimum parameter settings. Analysis of variance (ANOVA) was carried out also to determine the effects of each process parameter. At a 95% confidence interval, rotational and welding speed are significant parameters. The joint efficiency reached 92.25% of the base metal at optimum parameter settings. Additionally, the microstructure of the stir weld zone of the specimen was studied as well. Metallographic characterization carried out using a scanning electron microscope (SEM) revealed the microstructure of the samples after the weld did not show much significant change with the base metal.
Highlights
The firm's everlasting joining of materials is one of the key measures in the engineering processes
Fusion welding is one of in the record, usually used in the conventional joining practices. This method is pigeonholed by high-temperature gradients, leading to high thermal stress and prompt solidification, which escalates the occurrence of the segregation phenomenon [1]
The aviation industry uses AA 6061 to make commercial and military aircraft parts such as wings, fuselages, and airframe mountings [15,16,17]. Most transportation sectors such as aviation, automotive, and Maritimes use friction stir welding to reduce the manufacturing time of components, enhance the thermo-mechanical properties, boost the joint strength compared to fusion welding, and minimize the weight of weld joints [18]
Summary
The firm's everlasting joining of materials is one of the key measures in the engineering processes. The latest and advanced joining process offers several benefits, for the joining of lightweight materials, among which Friction Stir Welding (FSW) is a prominent joining process [5, 6]. It is a solid-state joining process developed by W. Most transportation sectors such as aviation, automotive, and Maritimes use friction stir welding to reduce the manufacturing time of components, enhance the thermo-mechanical properties, boost the joint strength compared to fusion welding, and minimize the weight of weld joints [18]. The result revealed that the experimental temperature results are very close to the predicted simulation temperature results
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