International Journal for Scientific Research & Development

IJSRD - International Journal for Scientific Research & Development| Vol. 4, Issue 02, 2016 | ISSN (online): 2321-0613

Effect of process parameters by Friction Stir Welding Harsh Raval1 Chirag Tejnani2 Deepu Rakholiya3 Vinit Patel4 Diptesh Patel5 1,2,3,4UG Student 5Assistant Professor 1,2,3,4,5Department of Mechanical Engineering 1,2,3,4,5S.V.B.I.T. VASAN Abstract— Aluminium alloys which exhibits very attractive 5) Solid state welding mechanical, physical and chemical properties have intensive  Friction welding demand in various areas especially marine structure. In  Ultrasonic welding order to join aluminium alloys various welding methods are  Diffusion welding employed but the recent innovative and environmental  Explosive welding friendly techniques is friction stir welding. In this study thin  Cold welding aluminium alloy plates of Al 6061 has been joined using  Forge welding friction stir welding. The factors which influencing the 6) New welding processes welding parameter are spindle speed and transverse feed  Electron beam welding which are varied to 700, 800, 900 rpm and 18, 29, 45  Laser beam welding mm/min. The 6mm thick plates are joined. The weldment is achieved using a cylindrical tool of pin diameter 6mm. The C. Friction Stir Welding effect of welding parameters chosen are evaluated using Friction stir welding (FSW) is a solid-state joining technique tensile testing to know the properties and ductility of a which was invented at The Welding Institute (TWI), UK, in weldment. 1991.The FSW has been found to be effective for joining Key words: Friction Stir Welding, Al 6061, Cylindrical hard-to-weld metals and for joining plates with different Tool, Feed, Spindle Speed, Ultimate Tensile Strength thickness or different materials. In the FSW process a non-consumable rotating tool I. INTRODUCTION with a specially designed pin and shoulder is inserted into A. Welding the edges of workpieces to be joined and traversed along the line of the joint. As the tool travels, heat is created by the Welding is a process of permanent joint of two material contact friction between the shoulder and the workpiece, and components(usually metals) with or without application of by the plastic deformation of the materials in the stir zone. heat, with or without pressure and with or without filler The high strain and heat energies experienced by the base metal. A range of welding processes have been developed so metal during stirring causes dynamic recrystallization, far using single or a combination above factors namely heat, which is the formation of new grains in the weld zone. pressure and filler. Welding processes can be classified as follows: II. LITERATURE REVIEW B. Classification of Welding Effects of process parameters on the joint microstructure 1) Gas welding evolution of Al6061-T6 Ni (2014) observed that the Thin  Oxy acetylene or hydrogen welding sheets of aluminium alloy 6061-T6 and one type of  Air acetylene welding Advanced high strength steel, transformation induced 2) Arc welding plasticity (TRIP) steel have been successfully butt joined  Carbon arc welding using friction stir welding (FSW) technique. Tensile tests  Metal arc welding and scanning electron microscopy (SEM) results indicate  Gas metal arc welding(MIG) that the weld nugget can be considered as aluminium matrix  Plasma arc welding composite, which is enhanced by dispersed sheared-off steel  Electro slag welding fragments encompassed by a thin inter-metallic layer or  Submerged arc welding simply inter-metallic particles. Effects of process parameters on the joint microstructure evolution were analyzed based  Flux cored arc welding on mechanical welding force and temperature that have been  Gas tungsten arc welding(TIG) measured during the welding process.  Atomic hydrogen arc welding Effects of process parameters on self-reacting friction 3) Resistance welding stir welding of Al6061-T6 Liu a (2013) In their research, the  Butt welding 4 mm thick 6061-T6 aluminium alloy was self-reacting  Resistance butt welding friction stir welded at a constant tool rotation speed of 600  Spot welding r/min. The specially designed self-reacting tool was  Seam welding characterized by the two different shoulder diameters. The  Projection welding results of transverse tensile test indicated that the elongation  Percussion welding and tensile strength of joints increased with increasing 4) Thermo-Chemical welding welding speed. The defect-free joints were obtained at lower  Themit welding welding speeds and the tensile fracture was located at the  Atomic H2 welding heat affected zone adjacent to the thermal mechanically affected zone on the advancing side.

Effect of process parameters on Dissimilar AA6061 and etc. can be used in Friction Stir Welding. We have selected AA7075 alloy by FSWGuo (2013) Studied that the Al 6061 for this project after going through above literature Dissimilar AA6061 and AA7075 alloy have been friction surveys. stir welded with a variety of different process parameters. In  Properties of Al 6061:- particular, the effects of materials position and welding Density – 2.70 gm/cm^3 speed on the material flow, microstructure, micro hardness Young’s modulus – 69 Gpa distribution and tensile property of the joints were Max. tensile strength – 132 Mpa investigated.It was revealed that the material mixing is much Max. yield strength – 55 Mpa more effective when AA6061 alloy was located on the Melting point – approx. 580* Celcious advancing side and multiple vortexes centres formed Thermal conductivity – 173 W/mK vertically in the nugget.  Specification of the material:- Effects of process parameters on Friction Stir Welding of Length:-150mm Al6061-T6 aluminium alloy Bhatt (2013) In this research Width:-50mm we observed that Friction stir welding (FSW) of AA6061- Thickness:-6mm T6 aluminium alloy has been attempted to overcome limitations of fusion welding of the same. The FSW tool, by C. Friction Stir Welding not being consumed, produces a joint with predominant We have done the FSW by jointing the two plates of Al advantages of high joint strength, lower distortion and 6061 material of given specifications.And also by selecting absence of metallurgical defects. Process parameters such as the appropriate combinations which we have derived from tool rotational speed, tool traverse speed and axial force and Mini Tab software(Table is shown in below section).So we tool dimensions play an important role in obtaining a get the welding just like as shown in figure. specific temperature distribution and subsequent viscosity distribution within the material being welded; the former controlling the mechanical properties and later the flow stresses within the material in turn. Effect of process parameters on friction-stir-welded AA6061 aluminium alloy joints by RSMS. Rajakumar et al. (2011) observed that AA6061 aluminium alloy has gathered wide acceptance in the fabrication of light weight structures requiring high strength-to-weight ratio and good corrosion resistance. Friction-stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process Fig. 1: Friction Stir Welding uses a non-consumable tool to generate frictional heat in the abutting surfaces. The FSW process and tool parameters D. Testing(Tensile) play a major role in deciding the joint strength. Joint We have tested all our FSW experiments in Ultimate Tensile strength is influenced by grain size and hardness of the weld Machine(UTM).For testing we have to cut all the nugget region. Hence, in this investigation an attempt was experiments in to I-sections. One of the I-section is shown in made to develop empirical relationships to predict grain size the figure. Then, by testing all the experiments we get all the and hardness of weld nugget of friction-stir-welded AA6061 ultimate tensile testing results as shown in the below table. aluminium alloy joints. The empirical relationships are developed by response surface methodology incorporating FSW tool and process parameters. A linear regression relationship was also established between grain size and hardness of the weld nugget of FSW joints.

III. METHODOLOGY A. Selection of process parameters. Many process parameters affect the FSW. But after getting knowledge of above literature papers we have selected spindle speed and feed as input parameters. And Ultimate Tensile strength as an output parameter.  Input Parameters Feed:- 18mm/min,29mm/min,45mm/min Speed:- 700rpm,800rpm,900rpm  Output Parameter Ultimate Tensile Strength Fig. 2: I-Section of FSW plate B. Material selection Various non-ferrous materials like Magnesium, Aluminium(Al 6061-T4,Al 6061-T6,Al 6061,etc), Copper

Fig. 3: Final Table of UTM

Fig. 6: graph of UTM IV. ANALYSIS A. Data generated automatically by analysis of the UTM in we have done analysis of given input parameters(speed and Mini Tab: feed) and UTM by using Mini Tab software.The analysis reports are shown below.The analysis is done by using S = 3.55804 PRESS = 729.660 uncoded units. R-Sq = 91.54% R-Sq(pred) = 30.33% R-Sq(adj) = 85.50% Analysis of Variance for UTM

V. COMPONENTS A. Tool Various tools like Cylindrical, Square , Triangular , TriFlute Fig. 4: graph of feed etc. are used in Friction Stir Welding. We have selected cylindrical tool. Materials such as aluminium or magnesium alloys, and aluminium matrix composites (AMCs) are commonly welded using steel tools. Tool geometry is also shown in the figure.

Fig. 5: graph of speed

Fig. 7: Cylindrical Tool

1) Response Surface Method The response surface method was introduced by G. E. P. Box and K. B. Wilson in 1951. The main idea of RSM is to use a sequence of designed experiments to obtain an optimal response. The application of RSM to design optimization is aimed at reducing the cost of expensive analysis methods (e.g. finite element method or CFD analysis) and their associated numerical noise. The response can be represented graphically, either in the three-dimensional space or as contour plots that help visualize the shape of the response surface. Levels(-1 to +1) and factors(speed and feed) of the input parameters are shown below. This is done by using RSM method. We can get different combinations of input Fig. 8: geometry and design of tool parameters for welding of our material by RSM method. Different combinations of input parameters are shown B. Fixture below. Fixture is required to hold the aluminum plates at the time of -1 +1 the welding. Also it is adjustable and removable when the Speed 700 900 welding is not performed on it. Feed 18 45 Table 1: Levels and Factors

Fig. 9: Fixture C. Hacksaw Hacksaw is required to cut the aluminum plates. Fig. 10: Table of RSM D. Vertical Milling Machine Vertical milling machine is required to perform Friction Stir VI. ADVANTAGES AND DISADVANTAGE Welding on it. The original class of machine tools for milling was the milling machine (often called a mill). A. Advantages: generally classified as vertical machining centers (VMCs)  Issues such as porosity, redistribution, solidification, and horizontal machining centers (HMCs).There are also cracking don’t arise during FSW other machines on which FSW can be performed.  No arc or fumes E. Ultimate Tensile Machine  Can operate in all position.  Easily automated on simple milling machine. This machine gives us the value of ultimate tensile strength  Excellent mechanical properties in fatigue, tensile and of the input material. This machine can be manually bend tests. operated or automatically operated. It is very much useful  Recrystalization with plastisization occurred during machine in the QC(Quality Control) department of the FSW. industries.  No melting occurred. F. Mini Tab  Higher accuracy and efficiency of welded material. The MiniTab is important in designing, formulating,  Better option for TIG and MIG welding. developing, and analyzing new scientific studies and  Low heat distortion and shrinkage effect. products. It is also efficient in the improvement of existing  No grinding, brushing and pickling required during studies and products. In this investigation MiniTab will be mass production. used to reduce the number of experiments, in addition to B. Disadvantages: build a numerical relation between the quality of welding and the welding parameter.  Sometimes lack of penetration defect

 Insufficient weld temperatures due to low rotational [5] T4 S.T. Amancio-Filho, S. Sheikhi,J.F. dos Santos, C. speeds or high transverse speeds. Bolfarini. Preliminary study on the microstructure and  Need backing support. mechanical properties of dissimilar friction stir welds in aircraft aluminium alloys 2024-T351 and 6056-journal VII. CONCLUSION of materials processing technology 2 0 6 ( 2 0 0 8 ) 132–142. With all the above reports and testing analysis we can say [6] Scialpi, L.A.C. De Filippis, P. Cavaliere. Influence of that Friction Stir Welding of the Al 6061 plates gives us shoulder geometry on microstructure and mechanical very much tensile strength. Also it is a great option for TIG properties of friction stir welded 6082 aluminium alloy. and MIG welding .Al 6061 is better material than other non Materials and Design 28 (2007) 1124–1129 ferrous alloys.By adjusting input parameters like feed and [7] F. Simoes a,b, D.M. Rodrigues b,⇑, Material flow and speed the output parameter varies accordingly. So, input thermo-mechanical conditions during Friction Stir parameters are very affecting during the Friction Stir Welding of polymers: Literature review, experimental Welding process on the output parameters. In these results and empirical analysis, Materials and Design 59 experiments the experiment with 900rpm speed and (2014) 344–351, Received 27 October 2013,Accepted 18mm/min. feed shows highest tensile strength. So, we can 16 December 2013,Available online 18 February 2014. see that with higher speed and lower feed combination gives [8] Hui-jie ZHANG, Hui-jie LIU, Lei YU, Thermal us the maximum output from the Friction Stir Welding modeling of underwater friction stir welding of high process. strength aluminum alloy, Trans. Nonferrous Met. Soc. China 23(2013) 1114_1122, Received 23 February ACKNOWLEDGEMENT 2012; accepted 26 June 2012. This research was supported by Mr. Maulik Patel. We thank [9] Kanwer S. Arora & Sunil Pandey & Michael Schaper our professor from Shankarsinh Vaghela Bapu Institue Of &Rajneesh Kumar Effect of process parameters on Technology who provided insight and expertise that greatly friction stir welding of aluminium alloy 2219-T87, assisted the research.We thank Mr. Maulik Patel for Springer-Verlag London Limited 2010, Received: 2 assistance with our guide (Mr. Diptesh Patel) for comments December 2009 / Accepted: 31 January 2010 / that greatly improved the manuscript. Published online: 20 February 2010. We would like to show our gratitude to Mr. Maulik [10] Sandra Zimmer & Laurent Langlois & Julien Laye Patel for sharing their pearls of wisdom with us during the &Regis Bigot. Experimental investigation of the course of this research, and we also thank them for their so- influence of the FSWplunge processing parameters on called insights. We are also immensely grateful to Mr. the maximum generated force and torque, Springer- Maulik Patel for their comments on an earlier version of the Verlag London Limited 2009, Received: 22 January manuscript, although any errors are our own and should not 2009 / Accepted: 22 June 2009 / Published online: 21 tarnish the reputations of these esteemed persons. July 2009. [11] http://www.iwegreifswald.de/bilder/vordergrund/rrs_vo REFERENCES rsaetze.jpg [1] Xun Liu, Shuhuai Lan, Jun Ni ⇑,Analysis of process [12] http://www.technologystudent.com/equip1/vert1a.gif parameters effects on friction stir welding of dissimilar [13] http://www.apsu.edu/sites/apsu.edu/files/news/2012092 aluminum alloy to advanced high strength steel, 7-Longhurst-welding-0285.jpg Materials and Design 59 (2014) 50–62, Received 22 [14] https://upload.wikimedia.org/wikipedia/commons/thum October 2013,Accepted 1 February 2014,Available b/c/c2/SawMachine.jpg/434px- online 7 February 2014. SawMachine.jpg?download [2] H.J. Liu a,⇑, J.C. Hou a,b, H. Guo a, Effect of welding [15] http://www.custompartnet.com/wu/images/milling/milli speed on microstructure and mechanical propertiesof ng-machine.png self-reacting friction stir welded 6061-T6 aluminum alloy, Materials and Design 50 (2013) 872– 878,Received 22 January 2013,Accepted 30 March 2013,Available online 11 April 2013. [3] J.F. Guo ⇑, H.C. Chen, C.N. Sun, G. Bi, Z. Sun, J. Wei, Friction stir welding of dissimilar materials between AA6061 and AA7075 Al alloys effects of process parameters, Materials and Design 56 (2014) 185–192, Received 12 August 2013,Accepted 29 October 2013,Available online 9 November 2013. [4] D.M. Rodrigues a,*, A. Loureiro a, C. Leitao a, R.M. Leal a,b, B.M. Chaparro a,c, P. Vilaça d, Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds,Materials and Design 30 (2009) 1913–1921, Received 21 July 2008,Accepted 9 September 2008,Availableonline 21 September 2008.