Investigate the Process Parameter on the Friction Stir Welding of Dissimilar Aluminium Alloys

Abstract

The welding of different materials with an acceptable quality range is an emerging study area; engineers and scientists worldwide have long been concerned with dissimilar welding materials. This study focuses on determining the friction stir welding of different aluminuim alloys; an experimental investigation was conducted (AA7475-T651 and AA2219-O). It also describes the FSW process parameters and response measurement for defining weld quality and the procedure for measuring them. Taguchi L27, orthogonal array method, is preferred for optimizing FSW parameters such as shoulder diameter, tool rotational speed, and traverse speed. The effect of welding parameters is investigated through the ANOVA table and graphs. The SEM analysis investigates the fracture and micrographic analysis in the heat-affected zone and thermo-mechanically affected zone.

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

“…These can be split into distinct categories [190]. The first category involves statistical approaches, such as Response Surface Methodology (RSM) [191][192][193], Taguchi [194][195][196][197], and ANOVA [198][199][200], which are used to determine the best parameters. The second group includes heuristic techniques such as genetic algorithms (GA), simulated annealing (SA), artificial neural networks (ANN), and adaptive neuro-fuzzy inference systems (ANFIS) that are used to optimize the responsiveness and value of parameters.…”

Correlation of microstructure, texture, and mechanical properties of friction stir welded Joints of AA7075-T6 plates using a flat tool pin profile

“…Moreover, an enlarged shoulder diameter not only improves the tool's heat-carrying capacity but also increases frictional heat. An escalation in traverse speed elevates the strain rate and reduces the temperature in the weld zone, leading to the formation of a fine grain structure [ 52 , 53 ]. Following intense plastic deformation and exposure to elevated temperatures, the weld zone may undergo dynamic recovery and dynamic recrystallization.…”

“…Following intense plastic deformation and exposure to elevated temperatures, the weld zone may undergo dynamic recovery and dynamic recrystallization. This process results in a highly refined grain structure within the weld zone region and accordingly dimension and shape of stir zone changes [ 51 , [52] , [53] , [54] ]. The defect-free, good material mixing, and ultra-fine gain refined in the SQ-shaped FSW tool pin result in improvements in the tensile strength and mechanical properties of the joint, which will be further discussed in the tensile stress-strain analysis of the weld specimen.…”

Experimental Studies on Mechanical Behavior of TIG and Friction Stir Welded AA5083 -AA7075 Dissimilar Aluminum Alloys

“…However, due to incompatibility in material properties like physical, chemical, and mechanical, joining of dissimilar materials or aluminum alloys could be a difcult task. Also, because of variation in thermal expansion coefcient and solidus temperature, there is a chance to fail even during the welding process [1,2]. Fusion-based and solid state welding techniques as well as other processes such as soldering and brazing can be successfully used to join aluminum alloys.…”