Characterization and optimization of process parameters on FS welded joints for AA 6023 – T6 aluminium alloy and pure copper

Abstract

Friction Stir Welding (FSW) is a solid-state welding process innovated and patented by Wayne Thomas in 1991, at London; the Welding Institute (TWI), used to join metals as well as non metals in form of butt and lap weld joints. The fundamental concept of this joining process is done by non-consumable rotating tool consists of shoulder and pin by fixing the base materials on the bed of CVMM with a fixture and backing plates. The workpieces were joined together by heat, material movement, and forging action. FSW process has a wide industrial application like automobile, aerospace, marine and fabrication industries. The aim of this thesis is to characterize mechanical properties and optimize the process parameters of AA 6023 – T6 – Cu dissimilar FS welded joints of 2mm thickness. For an adoption of FSW process on conventional vertical milling machines; FSW tool, backing plates and fixtures were designed. Optical microscope, tensile and hardness machines used to test microstructure, tensile strength and hardiness tests. The quantitative sampling approach is used and the results are taken from machines for 27 sampling size of 9 welded joints. The sound and defect free as well as good grain refinement of the weld joint is obtained at an optimum FSW process parameters for AA 6023–T6 aluminium alloy and pure Cu sheets are chosen at 1600 rpm rotational speed, 12.5mm/min transverse Speed and 2mm tool pin setoff. At an optimized combination of process parameters, the main effect plot for the S/N ratio and mean the Optimized Tensile Strength and hardness value has predicted as 170.40 MPa and 118.41 HV respectively.Friction Stir Welding (Fsw) Is A Solid-State Welding Process Innovated And Patented By Wayne Thomas In 1991, At London; The Welding Institute (Twi), Used To Join Metals As Well As Non Metals In Form Of Butt And Lap Weld Joints. The Fundamental Concept Of This Joining Process Is Done By Non-Consumable Rotating Tool Consists Of Shoulder And Pin By Fixing The Base Materials On The Bed Of Cvmm With A Fixture And Backing Plates. The Workpieces Were Joined Together By Heat, Material Movement, And Forging Action. Fsw Process Has A Wide Industrial Application Like Automobile, Aerospace, Marine And Fabrication Industries. The Aim Of This Thesis Is To Characterize Mechanical Properties And Optimize The Process Parameters Of Aa 6023 ?�? T6 ?�? Cu Dissimilar Fs Welded Joints Of 2mm Thickness. For An Adoption Of Fsw Process On Conventional Vertical Milling Machines; Fsw Tool, Backing Plates And Fixtures Were Designed. Optical Microscope, Tensile And Hardness Machines Used To Test Microstructure, Tensile Strength And Hardiness Tests. The Quantitative Sampling Approach Is Used And The Results Are Taken From Machines For 27 Sampling Size Of 9 Welded Joints. The Sound And Defect Free As Well As Good Grain Refinement Of The Weld Joint Is Obtained At An Optimum Fsw Process Parameters For Aa 6023?�?T6 Aluminium Alloy And Pure Cu Sheets Are Chosen At 1600 Rpm Rotational Speed, 12.5mm/Min Transverse Speed And 2mm Tool Pin Setoff. At An Optimized Combination Of Process Parameters, The Main Effect Plot For The S/N Ratio And Mean The Optimized Tensile Strength And Hardness Value Has Predicted As 170.40 Mpa And 118.41 Hv Respectively.