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1. Introduction
The novel technique joins the material permanently by using the friction stir welding process, and the nonconsumable tool is applied to carry the welding process. One best advantage of the FSW process is, without melting the work samples during welding, heat is introduced between tool rotation and specimens [1–3]. The welding is carried out along the straight line in a longitudinal manner of tool movement to join the samples. The homogeneous mixture is achieved applying the pressure in the joint area (soft region) of the specimens. The FSW process effectively joins all alloys such as aluminium alloys, titanium alloys, copper alloys, magnesium alloys, and steel material by a similar or dissimilar mode. This welding is now fruitfully used in joining polymers, and the FSW process is carried out by Wayne Thomas at TWI Ltd. in 1991 [4–6]. Most of the aluminium alloy is used in the ship building, automotive segment, and aerospace sectors. The different tool profiles are used in friction stir welding as cylindrical, square triangular, and threaded, and the tool rotates and passes through a straight line mode [7]. The shoulder diameter is big in size compared to tool pin diameter, and the pin of the tool plunges into work pieces effectively [8]. The pin rotates at high speed with intercombination of materials carried out efficiently. The microstructure changed by means of stirring action; it causes the swap of particles from one material to another one remarkably. The strength of the joint is increased, and to form a rigid structure, the study of different zones in the welded area is very important in the friction stir welding process. In arc welding, gas welding and other types of the welding process formed lot of defects, but this FSW process eliminates or minimizes the welding defects if using any material with various parameters [9]. The FSW process is mainly used to make butt joint, eventhough lap joints are also carried in the FSW process. For the past research, the dissimilar friction stir welding of AA7079 and AA8050 is through response surface methodology. The influence of different process parameters is to evaluate the tensile strength of the weld joint successfully. RSM is a statistical technique to find the optimal parameters and the maximum range of the output value [10–12].
2. Materials
The friction stir welding process planned to make dissimilar aluminium alloy materials such as AA7079 and AA8050. The chemical composition of both the materials is tabulated with their weight percentage in Table 1.
Table 1
Chemical composition of AA7079 and AA8050.
Material | % of composition of AA7079 | % of composition of AA8050 |
Cr | 0.2 | 0.05 |
Cu | 0.6 | 0.05 |
Fe | 0.2 | 1.2 |
Mg | 3.5 | 0.05 |
Mn | 0.25 | 0.85 |
Si | 0.25 | 0.03 |
Zn | 4.0 | 0.1 |
Ti | 0.7 | — |
Al | Remaining | Remaining |
The aluminium alloy 7079 has a wrought alloy with a heat treatable mode, and it has extraordinary strength. It possesses good machinability and workability characters; this alloy is mainly used in the high stressed parts. In the air wings parts, this alloy played a major role in hydraulic function units. The AA8050 aluminium alloy has good strength easy to modify any shape; it has high corrosion resistance behaviour. This alloy can be used in the body building industries.
3. Experimental Procedure
The FSW process considers the process parameters, and all the factors and their values are given in Table 2.
Table 2
FSW factors and its values.
Notation | Factors | Low | High |
A | Tool speed (rpm) | 1000 | 2500 |
B | Tool pin diameter (mm) | 2 | 6 |
C | Welding speed (mm/min) | 50 | 300 |
D | Shoulder diameter (mm) | 10 | 20 |
The factors are tool speed (1000–2500 rpm), tool pin diameter (2–6 mm), welding speed (50–300), and shoulder diameter (10–20). The friction stir welding process specimens prepared under the dimensions are 100
[figure omitted; refer to PDF]
Figure 4 shows the maximum tensile strength obtained by interaction of pin diameter, the tool speed has fixed as 1700 rpm, the tool pin has 4 mm diameter, and the maximum tensile strength was obtained as 170 MPa. In this experiment, Figure 5 illustrates the maximum tensile strength offered by the welding speed interaction, the tool pin diameter is fixed as 4 mm, welding speed is 175 mm/min, and the maximum tensile strength obtained is 160 MPa. The welding speed graph in Figure 6 shows that the welding speed has fixed as 175 mm/min, the maximum tensile strength produced by shoulder diameter interaction. The shoulder diameter of 15 mm influenced to produce the maximum tensile strength as 138 MPa.
[figure omitted; refer to PDF][figure omitted; refer to PDF][figure omitted; refer to PDF]7. Conclusion
The dissimilar friction stir welding of AA7079 and AA8050 aluminium alloy jointed efficiently applying straight cylindrical tool. The response surface methodology was implemented to find the maximum tensile strength and the optimal parameters. The output of this experiment is drawn as follows:
(1) From the analysis of variance, in the liner model, the major contribution of tool pin diameter was 6.38%, in the square model, the tool pin diameter
(2) The maximum tensile strength 212 MPa was obtained by the influence of tool speed of 1750 rpm, tool pin diameter of 4 mm, welding speed of 300 mm, and shoulder diameter of 20 mm
(3) For the predicted analysis, the optimum factor of tool speed of 1000 rpm, tool pin diameter of 2.4 mm, welding speed of 300 mm/min, and shoulder diameter of 10 mm offered the maximum tensile strength of 211.48 MPa. The predicted tensile strength and the response optimized tensile strength values are near, since the four factors and the values of this evaluation were good.
(4) Further scope of this study was extended to conduct friction stir processing (FSP) to modify the surface structure of the dissimilar materials
Disclosure
It was performed as a part of the employment of Bule Hora University, Ethiopia.
Acknowledgments
The authors appreciate the supports from Bule Hora University, Ethiopia, and thank Saveetha School of Engineering, Chennai, for the technical assistance to complete this experimental work.
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Abstract
Aluminium alloy is widely used in engineering application, and it can be classified based on the constituent elements or alloying elements. Aluminium alloy is preferred for the nature of its tensile strength, ductility, and corrosion resistance in this research to make a dissimilar friction stir welding joint of aluminium alloys 7079 and 8050 materials. The tensile strength of the weld joint is estimated by the influence of the response surface methodology approach. The welding is carried out by preferred process parameters with a tool speed of 1000–2500 rpm, tool pin diameter of 2–6 mm, welding speed of 50–300 mm/min, and tool shoulder diameter of 10–20 mm. The ANOVA analysis and the prediction of tensile strength were conducted efficiently. From the RSM analysis, the tool pin diameter mostly modified the output of the result.
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1 Department of Electrical and Electronics Engineering, Sathyabama Institute of Science and Technology, Rajiv Gandhi Salai, Chennai, Tamil Nadu, India
2 Department of Mechanical Engineering, Sri Sairam Engineering College, Sai Leo Nagar West Tambaram, Chennai 44, Tamil Nadu, India
3 Department of Mechanical Engineering, Saveetha School of Engineering, SIMATS, Chennai 602 105, Tamil Nadu, India
4 Department of Mechanical Engineering, Bule Hora University, P.O. Box 144, Addis Ababa, Bule Hora, Ethiopia
5 Department of Electrical and Electronics Engineering, Holy Mary Institute of Technology and Science, Keesara-Bogaram-Ghatkesar Rd, Kondapur, Telangana 501301, India
6 Department of Mechanical Engineering, SRM Valliammai Engineering College, Kattankulathur SRM Nagar, Chennai 603203, Tamil Nadu, India
7 Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, Nizampet, Hyderabad, India