Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 – Optimization of process parameters using Taguchi technique |
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| Affiliation: | 1. Department of Mechanical Engineering, St. Joseph’s College of Engineering, Chennai, Tamilnadu, India;2. Department of Mechanical Engineering, Anna University, Chennai, Tamilnadu, India;3. Department of Mechanical Engineering, SSN College of Engineering, Chennai, Tamilnadu, India;4. Tagore Engineering College, Chennai, Tamilnadu, India;1. Institute of Welding, 16-18 B?ogos?awionego Czes?awa Street, 44-100 Gliwice, Poland;2. Miami University, Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH, United States;3. AGH University of Science and Technology, 30 Mickiewicz Ave, 30-059 Krakow, Poland;1. Department of Mechanical Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia;2. Centre of Advanced Manufacturing and Material Processing (AMMP Centre), University of Malaya, 50603 Kuala Lumpur, Malaysia;3. Department of Mechanical Engineering, Assiut University, 715116, Egypt;1. Department of Mechanical Engineering, College of Engineering Guindy, Anna University, Chennai. India;2. Center for Materials Joining & Research, Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar Chidambaram 608002, Tamilnadu, India |
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| Abstract: | The joining of dissimilar Al–Cu alloy AA2219-T87 and Al–Mg alloy AA5083-H321 plates was carried out using friction stir welding (FSW) technique and the process parameters were optimized using Taguchi L16 orthogonal design of experiments. The rotational speed, transverse speed, tool geometry and ratio between tool shoulder diameter and pin diameter were the parameters taken into consideration. The optimum process parameters were determined with reference to tensile strength of the joint. The predicted optimal value of tensile strength was confirmed by conducting the confirmation run using optimum parameters. This study shows that defect free, high efficiency welded joints can be produced using a wide range of process parameters and recommends parameters for producing best joint tensile properties. Analysis of variance showed that the ratio between tool shoulder diameter and pin diameter is the most dominant factor in deciding the joint soundness while pin geometry and welding speed also played significant roles. Microstructural studies revealed that the material placed on the advancing side dominates the nugget region. Hardness studies revealed that the lowest hardness in the weldment occurred in the heat-affected zone on alloy of 5083 side, where tensile failures were observed to take place. |
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