Optimization of process parameters in Friction Stir Welding of dissimilar aluminum alloys (AA6061–T6 and AA5052–H32)
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Date
2023-03
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Addis Ababa University
Abstract
Friction stir welding (FSW) is a solid-state welding method mostly used to join aluminum and aluminum alloys that has been used in aerospace, railway, automotive, and marine applications. This process is used for welding dissimilar aluminum alloys. Solid-state welding processes solve several problems that occur during fusion welding of Al-alloys like heat affected zone liquation cracking, porosity, and segregation.
Aluminum Alloys of two different series AA5052 and AA6061 thickness of 6mm are Friction Stir welded using process parameters like tool rotational speed (900,1100,1400) rpm, transverse speed (40,50,60) mm/min, and pin profiles (cylindrical, conical, and square). This thesis aims to optimize the mechanical and metallurgical properties of the above dissimilar combination to evaluate the performance and characteristics of the welded joints. The combined Taguchi and Grey relation analysis experimental method was chosen to construct the number of welding experiments. Analysis of variance was performed to obtain the effect of the parameters on the Friction Stir welded joints strength.
The plates are successfully welded, and the welded plates are tested at room temperature to examine their tensile strength and hardness. The findings indicate that the square pin profile, the rotational speed of 1400 rpm, and the transverse speed of 40 mm/min are the optimum parameters for joining these dissimilar joints. A fine and uniform distribution of strengthening precipitates was found in the stir zone.
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Friction Stir Welding, Parameter Optimization, Microstructure, Grey relation analysis, Pin profile, AA6061–T6 and AA5052–H32