Some studies on friction stir welding of dissimilar alloys

Abstract

Friction Stir Welding (FSW) is an efficient technique and environmental friendly that can be used to joining the metals. The solid-state assembly method developed for applications where the unique characteristics must be remembered. Processes of joining either similar or dissimilar materials using a non-consumable tool generate the sufficient heat at below the solidus temperature of base alloys. Specifically, it tends to be utilized for join high-quality aviation aluminum alloys and other than hard metallic alloys that viewpoint challenging to weld through conventional welding process. Two symmetric plates with same dimensions of two types of aluminum compounds AA7075-T6, AA5083-H111 and AA6061-T6 were used for the basic materials in this investigation. Welding process parameters are tool rotational speed (rpm) and translational speed (mm/min) different shapes of pin geometry such as cylindrical, cylindrical threaded and hexagonal pin profile. Three dimensional heat transfer analysis of joining dissimilar alloys were done by using finite element method. Response surface methodology employed by using central composite design with 27 runs, three parameters and three levels were to improve the mathematical model predict the mechanical properties of dissimilar joint. This investigation optimizes the welding process parameters to obtain the excellent mechanical properties of dissimilar alloys of the fabricated joint by using Grey Relation Analysis (GRA). The optimized parameter were analyzed based on the single output responses from the multi-objective techniques by using normalized greys and the parameters ranked on the basis of optimized GRA. Furthermore, validate the experimental runs by using optimal process conditions for achieving the quality of weld. newline