Stress Corrosion Cracking (SCC) is the initiation and slow growth of cracks under the influence of tensile stresses and aggressive corrosion environment. Al alloy 2014 T 651 was solution heat treated and stress-relieved. In the present work, Stress Corrosion Cracking (SCC) experimental arrangement has been used to test the severity of aluminium alloys under particular environmental conditions. Sound welds were obtained with Friction Stir Welding at rotational speed of 800 rpm and welding speed of 200 mm/min. Friction Stir Welds were cut into standard tensile specimens as per ASTM E8 standards. Time to failure of the welds were obtained using 3.5 wt% NaCl solution at pH 10 in 0.7 and 1.1 yields by Stress Corrosion Cracking. Vickers micro-hardness was taken along various regions of the weld. Optical micro-graphs and scanning electron fractographs were taken to analyse the fracture behavior and fracture morphology of Friction Stir Welded aluminium alloy specimens, subjected to Stress Corrosion Cracking.

Milling is the surface machining process by removing material from the raw stock using revolving cutters. This process accounts for a major stake in most of the Original Equipment Manufacturing (OEM) industries. This paper discusses optimizing process parameters for machining the AA 2014 T 651 using a vertical milling machine with coated cutting tools. The process parameters such as cutting speed, depth of cut, and type of the cutting tool with all its levels are identified from the previous literature study and several trial experiments. The Taguchi L9 Orthogonal Array (OA) is used for the experimental order with the chosen input parameters. The commonly used cutting tools in the machining industry, such as High-Speed Steel (HSS) and its coated tools, are considered in this study. These tools are coated with Titanium Nitride (TiN) and Titanium Aluminum Nitride (TiAlN) by Physical Vapor Deposition (PVD) technique. The output responses such as cutting forces along the three-axis are measured using a milling tool dynamometer for the corresponding input factors. The input process parameters are optimized by considering the output responses such as MRR, machining torque, and thrust force. Grey Taguchi-based Response Surface Methodology (GTRSM) is used for multiobjective multiresponse optimization problems to find the optimum input process parameter combination for the desired response. Polynomial regression equations are generated to understand the mathematical relation between the input factor and output responses as well as Grey Relational Grade (GRG) values. The optimum process parameter combination from the desirability analysis is the HSS tool coated with TiAlN at a cutting speed of 270 rpm and a depth of cut value of 0.2 mm.

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