Improvement in joint efficiency with high productivity and narrow weld formation in friction stir welding

Abstract

High productivity, excellent joint strength and small weld bead make friction stir welding an emerging joining technique to join difficult to weld dissimilar aluminum alloys. Effect of rotational speed, traverse speed and shoulder diameter on the joint strength and elongation of the friction stir welded dissimilar aluminum alloys (AA7475-AA2219) is investigated. In addition, parameters are optimized to obtain joint with narrow weld bead and high joint efficiency using the entropy-weighted technique for order of preference by similarity to ideal solution method. Nine experiments are performed as per the L9 orthogonal array and mechanical properties of the welded joints are measured. Results of the study reveal that optimum values of ultimate tensile strength and percentage elongation are obtained at a rotational speed of 710 rev/min, welding speed of 250 mm/min and shoulder diameter of 10 mm resulting in good joint strength, high productivity and narrow weld bead. From the selected process parameter range, tool shoulder diameter is found to be the most significant parameter. The findings of the present study are discussed in light of the friction stir welding process mechanism, available literature, mechanical testing, microstructure and fractography.

Mechanical and Corrosion Properties of Friction Stir Welded and Tungsten Inert Gas Welded Phosphor Bronze

“…The FSW operations were performed on a vertical milling machine (model: FN2 -knee type milling machine, speed range: 35.5-1800 rpm and number of feeds: 18), providing a stable and controlled platform for the welding process. A non-consumable carbide tool with a pin length of 3.4mm, a pin diameter of 2.5mm with a pentagonal profile and a shoulder diameter of 25mm with a flat face is adopted for this work [36][37][38][39]. The pentagonal profile provides maximum distortion in the stir zone and will help attain a refined grain structure.…”

Microhardness and corrosion properties of friction stir welded phosphor bronze

“…notably, this alloy boasts superior thermal and electrical conductivity, a crucial attribute that finds practical utility in heat exchangers and electrical connectors. the myriad characteristics of phosphor bronze collectively position it as the preferred material across industries that demand a harmonious blend of strength, corrosion resistance, wear resilience, machinability, and aesthetic allure [2].…”