Dog-bone Specimens Research Articles

The role of coherent nano precipitates on stacking fault and deformation twin formation during tensile deformation of wire arc additive manufactured nickel-aluminum-bronze

The strain hardening mechanisms and dislocation interactions of a wire arc additively manufactured (WAAM) nickel-aluminum-bronze (NAB) alloy was investigated using multi-scale characterization approach cross-correlating scanning electron microscopy (SEM), SEM-based electron back-scatter diffraction (EBSD), site- and crystallographic orientation-specific focused ion beam (FIB) nanofabrication, scanning transmission electron microscopy (STEM) and STEM-based energy dispersive X-ray spectroscopy (EDS). Flat, rectangular dog bone specimens were strained under uniaxial tension conditions. To understand the micro- and nanometer scale deformation mechanisms throughout the microstructure, tensile test specimens were interrupted near the yield strength and ultimate tensile strength. STEM microstructural characterization revealed that tensile deformation occurs by planar slip and multiple slip bands interacting on different {111} planes as well as the nucleation of dislocations from the interfaces associated with grains and secondary phase particles. To the authors knowledge for the first time the Center of symmetry (COS) analysis revealed that in both samples the shearing of nanoscale precipitates led to the formation of extended stacking faults including a combination of intrinsic stacking faults and 2-layer extrinsic stacking faults. At high strain levels more dislocations and stacking faults were nucleated, as well as intersecting slip bands further facilitating the activation of the stair-rod cross-slip mechanism and thickening of an ESF to create a 3-layer nano-twin. Activated mechanisms of plastic deformation and associated role of the precipitates are discussed with respect to the microscopic strength-plasticity characteristics as well as macroscopic mechanical properties of WAAM NAB alloy.

Characterization of the mechanical properties of a polyurethane adhesive: Tensile strength and Fracture tests

The aim of this paper is to study the response of a polyurethane-based adhesive when subjected to different loading conditions. To achieve this, double cantilever beam (DCB) and dogbone specimens were manufactured, and tensile strength, fracture and fatigue fracture tests were performed. The results of the tensile tests revealed a tensile strength of 14.5 MPa and an elastic modulus of 0.27 GPa for the studied polyurethane adhesive. The analysis of the fatigue tests showed that fatigue crack growth starts to stabilize after 20% of the test is done, and that the adhesive used is more suitable for static loading conditions than for cyclic loading conditions, since the value of the average , 0.2 N/mm, is much lower than the value of the average , 4 N/mm.

Application of inverse heat transfer to fatigue fracture

Cyclic actuation tends to cause self-heating in the material as the structure experiences fatigue, where the movement and coalescence of defects lead to crack formation, propagation, and eventual fracture. This study explores the modeling aspects of the self-heating phenomenon using a one-dimensional inverse heat problem to analyze heat generation and dissipation to quantify the plastic work rates needed for predicting fatigue life. The approach is based on analyzing the surface thermography obtained using an infrared camera and numerically solving an inverse Fourier heat conduction equation. Formulation of the inverse problem via constrained optimization and method of solution for analyzing the fatigue behavior of CS 1018 flat dog bone specimens subjected to fully reversed bending fatigue are presented. The proposed model demonstrates superior accuracy in predicting the location of maximum heat generation and identifying potential fracture zones compared to traditional methods.

Feasibility assessment of non-contact acoustic emission monitoring of corrosion-fatigue damage in submerged steel structures

Corrosion-fatigue is considered to be one of the main degradation mechanisms affecting the structural integrity of offshore support structures. This paper presents a feasibility assessment for the detection and monitoring of corrosion-fatigue damage using non-contact acoustic emission (AE). An accelerated corrosion-fatigue experiment was conducted on a S420NL dog-bone specimen. A corrosion-fatigue cell was designed and fabricated to simultaneously apply accelerated corrosion and cyclic loads on the specimen submerged in artificial seawater. A three-electrode electrochemical configuration under potentiostatic control was used to accelerate corrosion. The ultrasound signals were continuously measured using underwater AE transducers (in the frequency range of 50–450 kHz) placed at a fixed distance from the tested coupon. The results of the accelerated corrosion-fatigue experiment suggest that corrosion-fatigue-induced ultrasound signals can be detected with a satisfactory signal-to-noise ratio using non-contact AE sensors. The mean energy of the corrosion-fatigue-induced ultrasound signals was one order of magnitude higher than that of the corrosion-induced signals. The trends of the AE parameters extracted from the AE signals were analysed as functions of the load cycles. The results revealed high potential for the identification and monitoring of corrosion-fatigue damage using the non-contact AE technique.

Effects of Infill Density and Printing Speed on The Tensile Behaviour of Fused Deposition Modelling 3D Printed PLA Specimens

The mechanical properties such as tensile behavior of a 3D printed object can be influenced by various printing parameters, including printing temperature, orientation, infill density, and printing speed. This study focuses on investigating the effects of infill density and printing speed. Thirty dog-bone specimens were 3D printed using Fused Deposition Modelling (FDM) technique with Polylactic Acid (PLA) filament. Three different infill density settings (40%, 60%, and 80%) and three printing speed settings (30 mm/s, 60 mm/s, and 90 mm/s) were used. Tensile tests were performed on each specimen using a Universal Testing Machine. The experimental results indicate a clear trend of tensile behaviour with infill density. Increasing the infill density leads to improved tensile behaviour in the specimen. The highest Young’s Modulus and ultimate tensile strength (UTS) were achieved at 541.67 MPa and 24.3 MPa, respectively, with an infill density of 80%. On the other hand, printing speed showed an inverse relationship with tensile behaviour. As the printing speed increased, the Young’s Modulus and UTS decreased. However, the effect of printing speed on the mechanical properties was not as significant as that of infill density. When increasing the printing speed from 30 mm/s to 90 mm/s, the UTS only decreased by 5.61%. In contrast, increasing the infill density from 40% to 80% resulted in a UTS increase of 35.23%.

Contribution of geometrical infill pattern on mechanical behaviour of 3D manufactured polylactic acid specimen: Experimental and numerical analysis

Additive manufacturing is regarded as a very efficient fabrication technique since it permits the manufacturing of any three-dimensional product. The present work determines the effect of various infill pattern on the mechanical properties in term of tensile strength, yield strength and hardness of poly-lactic acid (PLA) samples fabricated by fused deposition modeling method. The mechanical behaviour of the 3D-printed PLAs investigated using dog-bone specimens with six distinct infill patterns: line, triangle, tri-hexagon, cubic, octet, and gyroid. The mechanical characteristics were evaluated using the uniaxial tensile test and shore D type hardness tester. The strain and deformation criteria were employed to substantiate the ductile and brittle characteristics. The fractural surface morphology analyzed using the field emission scanning electron microscope. Nonlinear Finite Element Analysis (FEA) was employed to simulate the uniaxial tensile test and establish a Yeoh third order hyperelastic material model for the predictions of the stress-strain response. This model is chosen for its precise ability to predict the nonlinear stress-strain responses for significant deformation and is crucial in applications that involve high degrees of flexibility and elasticity, such as in tire modeling, polymer and elastomer analysis, sports equipment designing, 3D printed components etc. Results revealed that the cubic infill had a maximum tensile strength 32.648 ± 1.42 MPa and octet infill had a minimum tensile strength 22.373 ± 0.79 MPa. The majority of experimental data indicated a brittle behaviour for line-infilled, but triangular, trihexagonal, cubic, octet, and gyroid infill patterns demonstrated ductile behaviour. In comparison to other geometrical infills, cubic shown relatively superior mechanical responses. Consequently, the geometrical infill effect plays a significant role in finding the appropriate mechanical property for industrial applications. The developed material model possesses potential utility in non-linear FEA investigations pertaining to 3D printed PLA objects that are predicted to sustain tensile strength.

Improving the compatibility of polylactic acid/polycarbonate blends with nanoclay and Joncryl as chain extenders

AbstractThis study aimed to optimize the compatibility and performance of PLA/PC blends by investigating the effects of Cloisite 20A nanoclay (NC) and Joncryl chain extender (CE). PLA/PC blends with varying NC and CE loadings were prepared, and the optimal formulation was identified. The optimal NC and CE content were then used to produce PLA/PC blends with varying PC ratios. The test specimens were produced by mixing the mixture in a twin‐screw micro compounder and subsequent injection molding into dog bone specimens to investigate the thermal, mechanical, and morphological properties of the blends. Scanning electron microscopy and dynamic mechanical analysis confirmed the immiscibility of the unmodified blend, but significant improvements in blend morphology were observed with high NC/CE ratios. The presence of NC/CE resulted in reduced droplet size of dispersed PC phase and a new intermediate glass transition temperature (Tg) in DMA, suggesting partial miscibility. The highest thermal stability improvement was achieved with 5 wt% NC alone or a combination of 5 wt% NC and 1 wt% CE. Composites containing NC/CE showed the most significant improvements in composite properties, demonstrating their effectiveness as compatibilizers and improved compatibility in PLA/PC blends. These results indicate that the use of NC/CE is a promising method for expanding the applicability of PLA/PC blends.

Influence of curing conditions on the interface bonding properties of CFRP plate–steel

To understand the influence of different curing conditions on the interface bonding performance of CFRP-reinforced steel plates, tensile tests were conducted on epoxy resin dog bone specimens and CFRP-reinforced steel plate double lap specimens. The study explored the tensile performance of dog bone specimens under different curing temperature/time conditions and the mechanical properties of double lap specimens under different curing pressures and curing temperature/time conditions. The results indicate that increasing the curing temperature can shorten the curing time of dog bone specimens and also improve their elastic modulus and tensile strength. Elevating the curing pressure, curing temperature, and extending the curing time cause a transition in the failure mode of the double lap specimens from surface fiber stripping of the CFRP plate to a mixed failure dominated by surface fiber stripping and adhesive–steel interface debonding, and the bearing capacity, interface ultimate slip, and peak shear stress of the specimens significantly increase, with the shear stress concentration zone gradually expanding from the loading end towards the free end, simultaneously, the ductility of the specimen increased, and the failure process was delayed. The ultimate load, interface peak shear stress, and ultimate slip of the specimens cured at 90 °C are significantly higher compared to the control group cured at 20 °C and 0.01 MPa. However, with increasing curing time, the rate of growth shows a decreasing trend.

Effects of intergranular deformation incompatibility on stress state and fracture initiation at grain boundary: Experiments and crystal plasticity simulations

The heterogeneous deformation of polycrystalline metals inherently originates from the intergranular deformation incompatibility. This paper proposes physical parameters related to the crystal orientations, the Schmid factor of the most activated slip system, and the misorientation angle to characterize the deformation incompatibility between the adjacent grain couple. A comprehensive multiscale investigation is conducted to reveal the mechanism from intergranular deformation incompatibility to fracture initiation at grain boundaries. At the specimen scale, experimental and numerical uniaxial tensile tests are performed on smooth and pre-notched dog-bone specimens to achieve different loading paths on the materials. The heterogeneous fields of stress triaxiality explains the heterogeneous size of the dimples observed in fractography. At the grain scale, electron backscatter diffraction analysis is conducted to characterize the microstructural properties around the nucleated voids within the materials. Voids are captured at the grain boundaries with directions parallel to the loading direction and intergranular deformation incompatibility is characterized using the proposed parameters. Simulations on the plastic deformation of realistic microstructures are performed to clarify the phenomenon. The results reveal that the fluctuation in stress triaxiality at grain boundaries is ascribed to intergranular deformation incompatibility, leading to fracture initiation at these sites. The relationships between the proposed physical parameters of intergranular deformation incompatibility and fluctuation in stress triaxiality are summarized in all circumstances. Finally, the ductile damage at the grain scale is predicted by the Rice–Tracey model, and the results show that the effects of microstructures on heterogeneous plastic deformation and stress state can be well considered.

Wood Polymer Composite Based on Poly-3-hydroxybutyrate-3-hydroxyvalerate (PHBV) and Wood Flour-The Process Optimization of the Products.

This study involved the optimization of the molded pieces manufacturing process from a poly-3-hydroxybutyrate-co-3-hydroxyvalerate biocomposite containing 30% wood flour by mass. The amount of wood flour and preliminary processing parameters were determined on the basis of preliminary tests. The aim of the optimization was to find the configuration of important parameters of the injection process to obtain molded pieces of good quality, in terms of aesthetics, dimensions, and mechanical properties. The products tested for quality were dog bone specimens. The biocomposite was produced using a single-screw extruder, whereas molded pieces were made using an injection molding process. The Taguchi method was applied to optimize the injection molding parameters, which determine the products quality. Control factors were selected at three levels. The L27 orthogonal plan was used. For each set of input parameters from this plan, four processing tests were performed. The sample weight, shrinkage, elongation at break, tensile strength, and Young's modulus were selected to assess the quality of the molded parts. As a result of the research, the processing parameters of the tested biocomposite were determined, enabling the production of good-quality molded pieces. No common parameter configuration was found for different optimization criteria. Further research should focus on finding a different range of technological parameters. At the same time, it was found that the range of processing parameters of the produced biocomposite, especially processing temperature, made it possible to use it in the Wood Polymer Composites segment.

Development of bone surrogates by material extrusion-based additive manufacturing to mimic flexural mechanical behaviour and fracture prediction via phase-field approach

Background and objectiveThe limited availability of human bone samples for investigation leads to the demand for alternatives. Bone surrogates are crucial in promoting research on the intricate mechanics of osseous tissue. However, solutions are restricted to commercial brands, which frequently fail to faithfully replicate the mechanical response of bone, or oversimplified customised simulants designed for a specific application. The manufacturing and assessment of reliable bone surrogates made of polylactic acid via material extrusion-based additive manufacturing are presented in this work. MethodsAn experimental and numerical study with 3D-printed dog-bone and prismatic specimens was carried out to characterise the polymeric feedstock and analyse the influence of process parameters under three-point bending and quasi-static conditions. Besides, three porcine rib samples were considered as a reference for the development of the artificial bones. Bone surrogates were manufactured from the 3D-scanned real bone geometries. In order to reproduce the trabecular and cortical bone, a lattice structure for the infill and a compact shell surrounding the core were employed. Infill density and shell thickness were evaluated through different printing configurations. Additionally, a computational analysis based on the phase-field approach was conducted to simulate the experimental tests and predict fracture. The modelling considered homogenisation of the infill material. ResultsOutcomes demonstrated the potential of the presented methodology. Maximum force and flexural stiffness were compared to real bone properties to find the optimal printing configuration, replicating the flexural mechanical behaviour of bone tissue. Certain configurations accurately reproduce the studied properties. Regarding the numerical model, strength and stiffness prediction was validated with experimental results. ConclusionsThe presented methodology enables the manufacturing of artificial bones with accurate geometries and tailored mechanical properties. Furthermore, the described modelling strategy offers a powerful tool for designing bone surrogates.

Enhancing UHPC Tensile Performance Using Polystyrene Beads: Significant Improvements and Mechanisms.

This study investigates utilizing spherical polystyrene (PS) beads as artificial flaws to improve ultrahigh-performance concrete (UHPC) tensile performance using a uniaxial tensile test and explains the corresponding mechanisms by analyzing the internal material structure of UHPC specimens with X-ray CT scanning. With a hooked steel fiber volume fraction of 2%, three PS bead dosages were employed to study tensile behavior changes in dog-bone UHPC specimens. A 33.4% increase in ultimate tensile strength and 174.8% increase in ultimate tensile strain were recorded after adding PS beads with a volume fraction of 2%. To explain this improvement, X-ray CT scanning was utilized to investigate the post-test internal material structures of the dog-bone specimens. AVIZO software was used to analyze the CT information. The CT results revealed that PS beads could not only serve as the artificial flaws to increase the cracking behavior of the matrix of UHPC but also significantly optimize the fiber orientation. The PS beads could serve as stirrers during the mixing process to distribute fiber more uniformly. The test results indicate a relationship between fiber orientation and UHPC tensile strength.

On the optimized fused filament fabrication of polylactic acid using multiresponse central composite design and desirability function algorithm

Efficient optimization of polymeric materials in fused filament fabrication 3D printing (FFF 3DP) is crucial for productivity, cost reduction, resource conservation, consistency, and enhanced part performance. This study employed a multiresponse central composite design of experiments (CCD-DOE) with the desirability function algorithm (DFA) to optimize printing settings on polylactic acid (PLA) using a commercial FFF 3D printer. The goal was to identify optimal parameters for faster build time and reduced material usage in PLA part fabrication. The fabrication process involved computer-aided design and modeling of standard PLA dogbone specimens, meeting ASTM-D638 Type 1 tensile test standards. These specimens were then 3D printed using Ultimaker Green RAL 6018 PLA filament and a 2+ model printer set at varying print parameters. Reduced second-order polynomial models for printing time and PLA weight were generated using stepwise regression, eliminating noninfluential parameters. The models revealed that higher layer thickness, increased print speed, and lower infill density resulted in faster printing times, while lower infill density and higher layer thickness led to lighter PLA prints. DFA analysis determined the optimal settings as a layer thickness of 0.26–0.30 mm and an infill density of 35% for minimizing printing time and PLA weight. The stress–strain curves displayed characteristic high-strength, brittle behavior under tension, while tensile testing of optimized PLA parts revealed increased strength with low strain at the break when layers were aligned parallel to the applied force. These findings advance additive manufacturing and provide practical guidelines for high-quality 3D-printed PLA components. Optimizing FFF 3DP parameters enables efficient production with reduced time and material usage, enhancing cost-effectiveness and the fabrication of high-performance 3D printed products.

Recovery stress, bond resistance, and stiffness to slip of crimped SMA fibers with considering geometric variation

Bond resistance is critical for reinforcing fibers in cementitious materials. Recently, crimped shape memory alloy fibers (SMA) have been raised as candidates for providing abundant benefits such as improved strength, enhanced durability, and crack closing. This study aimed to examine the influence of wave-depth and wave-length of crimped SMA fibers on their bond behavior. The crimped fibers in this study were categorized in four groups based on the wave-length. Each group had four types of fibers that considered the ratio of wave-depth to wave-length (DLR). Thus, a total of sixteen types of fibers were prepared with variations in wave-length and wave-depth. The tensile test used bare crimped SMA fibers, while the pullout tests used half dog-bone specimens. After the tests, the finite element model was used to evaluate the interaction parameters that were difficult to measure in the experience test. The results showed that the fibers with the smallest wave-length showed the largest maximum bond resistance in the same dept-to-length ratio (DLR) group, and that values decreased with an increasing wave-length. In addition, the smallest wave-length fibers demonstrated the most effective stiffness. Furthermore, the finite element analysis discovered that the geometric friction coefficients of the crimped SMA fibers were affected significantly by the geometric variation. The longer wave-length fiber revealed the larger estimated frictional coefficient.

Expanding the scope of multiphase-flash sintering: Multi-dogbone configurations and reactive processes

In this work, we have expanded the possibilities of the multiphase-flash sintering (MPFS) technique by investigating several configurations that involve multiple dogbone specimens (ranging from 1 to 3) and multiple phases (also ranging from 1 to 3). Unlike the traditional MPFS approach using complex 3D or cylindrical samples, this new method allows for a direct comparison with the established conventional flash sintering technique. Our experimental results with dense 8-mol% Yttria-stabilized zirconia demonstrate a significant reduction in the onset temperature as the number of phases and dogbones increases. Building on these findings, we achieved the preparation of pure bulk specimens of SrFe12O19 for the first time through reactive multiphase-flash sintering.

A finite-deformation isotropic non-associative viscoplasticity/damage coupled thermodynamic model for ductile fracture of thick adhesive composite joint

This paper develops a finite-deformation isotropic non-associative viscoplasticity/damage coupled model to predict ductilefracture behaviors of thick adhesive composite joint within the framework of irreversible thermodynamics. First, a damage variable is introduced into the elastic constitutive model, along with the Drucker-Prager’s type yielding function and plastic potential function which take into account the variable hydrostatic pressure and non-associative plasticity. An exponential damage potential function is developed to derive the damage evolution law relating to the thermodynamic force. Second, both kinematic hardening and isotropic hardening are considered that are represented by the back stress, hardening stress and their conjugate relationships with the corresponding internal variables, derived by the Helmholtz free energy. Third, an extended version of the Perzyna’s type model is developed by incorporating an over-stress function to derive the consistency plasticity factor for the viscoplasticity/damage coupled model. Fourth, the strain, stress, back stress, thermodynamic force, damage variable and tangent modulus are updated within the corotated configuration in the integration procedure. To simplify numerical computation, the stress and strain at time n + 1 are initially updated using the frozen damage variable and the back stress at time n, and the latter two values are independently updated at time n + 1. Finally, the developed model and numerical algorithm by implicit FEA are employed to predict the strain, stress, back stress, damage and fracture behaviors of the dog-bone MMA specimens under tensile loads and the thick MMA ductile adhesive specimens under shear loads.

Investigation of Hydrogen Embrittlement of Haynes 617 and Hastelloy X Alloys Using Electrochemical Hydrogen Charging

This study explores the hydrogen embrittlement behaviour of two Ni-based superalloys using electrochemical hydrogen charging. Two types of tensile specimens with different geometry for the Haynes 617 and Hastelloy X alloys were electrochemically hydrogen-charged, and then a slow strain rate test was conducted to investigate the hydrogen embrittlement behaviour. Unlike the ASTM standard specimens, two-step dog-bone specimens with a higher surface-area-to-volume ratio showed higher sensitivity to hydrogen embrittlement because hydrogen atoms are distributed mostly on the surface area. On the other hand, the Haynes 617 alloy had a lower hydrogen embrittlement resistance than that of the Hastelloy X alloy due to its relatively large grain size and the presence of precipitates at grain boundaries. The Haynes 617 alloy primarily showed an intergranular fracture mode with cracks from the slip band, whereas the Hastelloy X alloy exhibited a combination of transgranular and intergranular fracture behavior under hydrogen-charged conditions.

Induced alterations driven compromised structural properties in additively manufactured products

PurposeAdditive manufacturing also known as 3D printing is an evolving advanced manufacturing technology critical for the new era of complex machinery and operating systems. Manufacturing systems are increasingly faced with risk of attacks not only by traditional malicious actors such as hackers and cyber-criminals but also by some competitors and organizations engaged in corporate espionage. This paper aims to elaborate a plausible risk practice of designing and demonstrate a case study for the compromised-based malicious for polymer 3D printing system.Design/methodology/approachThis study assumes conditions when a machine was compromised and evaluates the effect of post compromised attack by studying its effects on tensile dog bone specimens as the printed object. The designed algorithm removed predetermined specific number of layers from the tensile samples. The samples were visually identical in terms of external physical dimensions even after removal of the layers. Samples were examined nondestructively for density. Additionally, destructive uniaxial tensile tests were carried out on the modified samples and compared to the unmodified sample as a control for various mechanical properties. It is worth noting that the current approach was adapted for illustrating the impact of cyber altercations on properties of additively produced parts in a quantitative manner. It concurrently pointed towards the vulnerabilities of advanced manufacturing systems and a need for designing robust mitigation/defense mechanism against the cyber altercations.FindingsDensity, Young’s modulus and maximum strength steadily decreased with an increase in the number of missing layers, whereas a no clear trend was observed in the case of % elongation. Post tensile test observations of the sample cross-sections confirmed the successful removal of the layers from the samples by the designed method. As a result, the current work presented a cyber-attack model and its quantitative implications on the mechanical properties of 3D printed objects.Originality/valueTo the best of the authors’ knowledge, this is the original work from the team. It is currently not under consideration for publication in any other avenue. The paper provides quantitative approach of realizing impact of cyber intrusions on deteriorated performance of additively manufactured products. It also enlists important intrusion mechanisms relevant to additive manufacturing.

Anisotropic Hardening and Plastic Evolution Characterization on the Pressure-Coupled Drucker Yield Function of ZK61M Magnesium Alloy.

This paper studies the plastic behavior of the ZK61M magnesium alloy through a combination method of experiments and theoretical models. Based on a dog-bone specimen under different loading directions, mechanical tests under uniaxial tension were carried out, and the hardening behavior was characterized by the Swift-Voce hardening law. The von Mises yield function and the pressure-coupled Drucker yield function were used to predict the load-displacement curves of the ZK61M magnesium alloy under various conditions, respectively, where the material parameters were calibrated by using inverse engineering. The experimental results show that the hardening behavior of the ZK61M magnesium alloy has obvious anisotropy, but the effect of the stress state is more important on the strain hardening behavior of the alloy. Compared with the von Mises yield function, the pressure-coupled Drucker yield function is more accurate when characterizing the plastic behavior and strain hardening in different stress states of shear, uniaxial tension, and plane strain tension for the ZK61M alloy.

Efficiency Improvement of Friction Stir Welding Parameters on AZ91 Magnesium Alloy Joints

Abstract: Friction Stir Welding (FSW) is a solid-state welding that permits an intensive formof parts and geometries to be welded with great nature of joints. The use of high-quality Magnesium alloys is extending in shipbuilding industry, particularly for the advancementof naval warships, cruise ships, littoral surface craft and merchant ships. FSW advancementhas been seemed to have various focal points for the exploitation of Magnesium alloys structures, as it is a minimal effort welding process. The objective is to come across the optimum levels of the process parameters in which it yields maximum tensile strength andbetter hardness. A three-factor, three-level design is utilized for optimizing the FSW process parameters and a Taguchi L9 orthogonal array experimental set up is used to anticipate the responses. The system parameters considered are Rotational speed, Transverse speed and the Tool tilt angle. The Friction stir welding is processed for butt joining of Magnesium alloys (AZ91) plates with 6 mm thickness. Tensile testing is attempted on dog-bone kind test specimen for Magnesium alloys. Analysis of Variance (ANOVA) has been used to analyze the effect of different parameters regarding the responses. The microstructural attributes of the welded segments, including base metal, heat affected zone (HAZ), Thermo Mechanically Affected Zone (TMAZ) and Stir Zone (SZ) are examined through Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analysis carried out to quantify the chemical element allocation at the weld interface. The observed optimum condition for Magnesium alloys (AZ91) is 560 rpm, 60 mm/min and 1 degree.