Experimental investigation and optimization of FSW process parameter of dissimilar metal with zinc particle

Abstract

Friction stir welding (FSW) is a solid-state joining process developed at The Welding Insti tute (TWI) in 1991. FSW works by using a non-consumable tool, which is rotated and plunged into the interface of two workpieces. The objective of this research was the experi mental investigation and optimization of FSW process parameters for dissimilar metals with zinc particles. Mechanical properties such as hardness and tensile strength were analysed, and microstructural analysis of the joint was conducted using an optical microscope and SEM. In this research, the experiment was conducted to determine the effects of process pa rameters (travel speed, rotational speed, and zinc particle weight percentage) on mechanical properties, hardness, and tensile strength. Design of experiments was conducted to quantify and optimize the effects of process parameters on hardness and tensile strength. Designs were prepared based on the Taguchi L9 orthogonal array, and the significance of process parameters on the response was identified by analysis of variance (ANOVA). The results showed that hardness and tensile strength increased with increasing rotational speed and zinc particle weight percentage, and decreased with increasing travel speed. Hardness and tensile strength were highly affected by rotational speed and travel speed. The maximum Vickers hardness was 138 HV, and the maximum tensile strength was 186 Mpa. Predicted optimum parameters for hardness and tensile strength were recorded at a travel speed of 45 m/s, rotational speed of 1200 rpm, and zinc particle weight percentage of 20 %.Friction Stir Welding (Fsw) Is A Solid-State Joining Process Developed At The Welding Insti Tute (Twi) In 1991. Fsw Works By Using A Non-Consumable Tool, Which Is Rotated And Plunged Into The Interface Of Two Workpieces. The Objective Of This Research Was The Experi Mental Investigation And Optimization Of Fsw Process Parameters For Dissimilar Metals With Zinc Particles. Mechanical Properties Such As Hardness And Tensile Strength Were Analysed, And Microstructural Analysis Of The Joint Was Conducted Using An Optical Microscope And Sem. In This Research, The Experiment Was Conducted To Determine The Effects Of Process Pa Rameters (Travel Speed, Rotational Speed, And Zinc Particle Weight Percentage) On Mechanical Properties, Hardness, And Tensile Strength. Design Of Experiments Was Conducted To Quantify And Optimize The Effects Of Process Parameters On Hardness And Tensile Strength. Designs Were Prepared Based On The Taguchi L9 Orthogonal Array, And The Significance Of Process Parameters On The Response Was Identified By Analysis Of Variance (Anova). The Results Showed That Hardness And Tensile Strength Increased With Increasing Rotational Speed And Zinc Particle Weight Percentage, And Decreased With Increasing Travel Speed. Hardness And Tensile Strength Were Highly Affected By Rotational Speed And Travel Speed. The Maximum Vickers Hardness Was 138 Hv, And The Maximum Tensile Strength Was 186 Mpa. Predicted Optimum Parameters For Hardness And Tensile Strength Were Recorded At A Travel Speed Of 45 M/S, Rotational Speed Of 1200 Rpm, And Zinc Particle Weight Percentage Of 20 %.