Welding Process

EFFECT OF PROCESS PARAMETERS ON FRICTION STIR WELDING OF AA1100 AND AA6082

D.Rajesh Kumar1, P.Sarath Kumar2, H.Vishnu Prasad3

B.E Mechanical Engineering, Bannari Amman Institute of Technology

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Abstract: Dissimilar AA1100 and AA6082 alloy have been friction stir welded with a variety of different process parameters. The effect of rotational speed and welding speed in this welding constitutes as process parameters which lead to the investigation of microstructure, micro hardness distribution and tensile property of the joints. Fine grain refinement observed in the nugget zone of AA1100 and AA6082 layers. Three different speeds parameters used are 1200, 1400 and 1600 rpm among these 1600 rpm provides good tensile

A wear resistant tool is plunged first at the interface of the plates and move forward to form the weld. The advantages of FSW technique is no necessity for gas shielding for welding aluminium. Mechanical properties are proven to be excellent by FSW process. There is no fume, no porosity, no spatter and low thermal shrinkage of the metal. Welding dissimilar metals can be attempted by this unique process.

Friction Stir Welding can be used to join aluminum sheets and plates without filler wire or shielding gas. Material thicknesses ranging from 0.5 to 60 mm can be welded from one side at full penetration, without porosity or internal voids. Nowadays welding materials is chosen for non-ferrous materials and it has a broad range of materials. In this paper we have identified the effects of different process parameters on friction stir welding of aluminium 1100 and aluminium 6082 which is mostly used in aircrafts, aluminium 6082 is used in wing ribs which is costly and more weight when compared to aluminium 1100. So aluminium 1100 can be welded with aluminium 6082 by friction stir welding process and be

Table 3.1 Tensile Test Results

Sample no Tensile Strength

(N)

1 2222

2 2291

3 2473

4 2120

5 2548

6 2686

Fig 3.2 Graph for the tensile test results. From the results it is found that sample 6 shows the best result, that is the sample welded with 1600 rpm and 50 mm/min.

B. Hardness Testing Hardness is a measure of how resistant solid matter is to various kinds of permanent shape change when a compressive force is applied. It is given as the resistance to indentation value for the joints. Brinell Hardness test is conducted according to ASTM E 10 standards. The load applied is 250kgf and the diameter of the ball indentor is 5mm.

Table 3.2 Brinell Hardness Test Results

Sample no Brinell Hardness Number

(BHN)

1 76.3

2 68.8

3 84.9

4 56.8

5 56.8

6 62.4

Fig 3.3 Graph for the Brinell hardness test