Evaluating the Microhardness Profiles in Friction Stir Welding of Dissimilar Alloys

Abstract

Friction stir Welding (FSW) advancement is used generally in the utilization of present-day flying and vehicle industry for predominant fundamental mentioning. Such a joining technique is displayed to avoid serious twists and the made excess weights are exhibited as low when it is stood out from the traditional welding structure. In this research, focus on to identify the parameters that will provide the dissimiliar alloys of aluminium AA6061 and AA8011 with good microhardness properties. From the current study microhardness strength of dissimiliar alloys of aluminium varies with the rpm, feed rate and shoulder diameter of the tool. At 2000 rpm and 15mm/min welding speed strength of joints is low and at high rpm 2400 and welding speed 20mm/min micro hardness strength is always low but at a rotation speed of 2200 rpm and welding speed 20 mm/min maximum strength of the weld joint . Hence at high rotational speed rise in the temperature occurs and cause dissolution of precipitates which lowers the hardness and at low rotational speed less heat generation at the tool workpiece interface causing less refinement of grains which lower the hardness value. During tensile strength test fracture and cracks occurs at weld center line.

Introduction

I. INTRODUCTION

Friction stir welding (FSW) is a solid state welding below their melting point .Friction stir welding was  developed in 1991 by the welding institute (TWI). Manufacturing of product requires the joining of materials at one point or the other during the product manufacturing. The process of welding with two basic types: solid-state welding and fusion welding. In fusion welding process, the joining process involves melting of the surfaces to be joined and upon solidification, the two materials become metallurgically bonded together. Solid-state welding on the other hand, affects the joining of materials at a temperature far below the melting point of the materials being joined. Solid-state welding and material processing are advanced welding and material processing technique that is developed, Friction stir welding and friction processing belong to a family of solid-state welding and material processing method with similar modes of operation.

Saini et al., (2022) evaluated the FSW joint of magnesium alloy AZ61a, discovered that the maximum microhardness and tensile strength were seen 1800rpm and 2000 rpm respectively at a welding speed of  20mm/min. the development of equiaxed grains in the TMAZ and stir zone was revealed by microscope analysis of the joints due to the dynamic recrystallization.

Kimura et al., (2021) the author of this work examined the impacts of tensile strength on the weld face properties of friction stir welded joints between pure copper and stainless steel as well as the effect on the tensile strength at various friction welding setting.

Pratap Kumar J(2021) The literature review suggests that more research attempts were made to weld the combination of copper and aluminium alloys; therefore, different optimization techniques were to be studied to optimize welding process parameters.

 Kimura et al., (2020) In this review, the creators analyzed the impacts of joint elasticity at various welding conditions, as well as the impacts of rigidity on the weld faying surface properties of grinding welded joints between austenitic hardened steel (AISI 304) and unadulterated copper. inspected the joining peculiarity and the joint elasticity at various  welding conditions

Wang et al., (2019) The authors conducted a thorough investigation into the effects of linear friction welding parameters on the microstructure, texture distribution, and mechanical properties of titanium alloy joints made of Ti-6.5Al-3.5Mo-1.5Zr-0.3.

Reddy, (2017) The audit expected to evaluate the welding connection of AA1100 and Zr705 composite using restricted part examination. With respects to Friction stir welding AA1100 and Zr705 combination, it was settled that the assembling pressure should be 1.25 times the frictional strain. The survey perceived ideal working conditions for good scouring welding of AA1100 and Zr705 blend, deciding a frictional pressure of 25 MPa, frictional time of four seconds, rotational speed of 2000 rpm, and delivering type of 31.25 MPa.

The writing survey referenced above made it clear that while a lot of examination has been done on FSW for similar welding aluminium alloys but very work has been found to be on dissimilar Aluminium alloys and that needs to be indepth exploration. In this exploration work, effect of changing the speed and feed will evaluate as information factors for the welding joints.

II. EXPERIMENTATION

A. Research Objectives

To determine and evaluate the AA6061 and AA8011 joints Micro hardness of  FSW.

B. Material,Tool, and FSW Parameters 

In this experiment AA6061-T6 and AA 8011 alloys with dimension 150mm by 150mm by 6mm.

Table 1: Nominal composition ofAA6061

Table 2: Material properties

  Table.3:  Nominal composition of AA8011

Table .4 Material properties

VI. FUTURE SCOPE

The future scope of FSW of dissimilar alloys of aluminium AA6061 And AA8011 are 

1. Axial force can be varied to observe the effect on micro structure view 
2. Friction stir spot welding can be used along with pre heating process

VII. ACKNOWLEDGMENT

The author is very highly thankful to RIMT university for providing the platform for this research work

Conclusion

From the current study the micro hardness of dissimilar alloys of aluminium varies with the rpm ,feed rate and shoulder diameter of the tool. At 2000 rpm and 15mm/min welding speed is low and at high rpm 2400 and welding speed 20mm/min microhardness is always low but finally at a rotation speed of 2200 rpm and welding speed 20 mm/min maximum micro hardness of the weld joint . Hence at high rotational speed rise in the temperature occurs and cause dissolution of precipitates which lowers the hardness and at low rotational speed less heat generation at the tool workpiece interface causing less refinement of grains which lower the hardness value.

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Copyright

Copyright © 2024 Shahid Shafi, Dr Sachin Saini, Simranjit Singh. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.