Optimization of process parameters of friction stir welding for Al-Cu joints using Taguchi method. JSS MAHAVIDHYAPEETHA JSS ACADEMY OF TECHNICAL EDUCATION, NOIDA DEPARTMENT OF MECHANICAL ENGINEERING (original) (raw)

Friction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. Heat is generated by friction between the rotating tool and the workpiece material, which leads to a softened region near the FSW tool.As a solid state welding process, FSW is a largely defect free joining method with no hot cracking, porosity or solidification cracks Due to the lower temperatures of Friction stir welding there is a reduction in shrinkage and distortion in the material being joined in the experiment which is to be performed.In FSW there is no filler materials, flux or shielding gas required for aluminium alloys.FSW is environmentally friendly as it produces no fume, spatter, or UV radiation.It uses machine tool technology, making the process easy to automate, highly repeatable and reducing need for skilled welders and hence it is easy to performed. It can work in any position with the setup.FSW joins the 'non weldable' Aluminium alloy such as those from the 2xxx and 7xxx series.Over the past two decades numerous research studies have been undertaken in order to characterize the process in terms of mechanical & metallurgical characterization and its effect on mechanical properties such as yield strength, tensile strength and percentage of elongation and fatigue properties, material flow, mechanical response by numerical simulation, thermo-mechanical model, tool process parameters & the corrosion behaviour of a FSW joints. This is all discrete work & it is observed that there is no evidence of systematic work that leads to development of quality joint for similar as well as dissimilar metal welds based on systematic variation of tool geometry & measure process parameters .The objective of present research work aims to acquire the fundamental knowledge of the FSW process and to investigate the feasibility of incorporating this technology with existing resources to weld aluminium alloys in the abutting configuration.