Experimental of tailor welded blanks fabricated using friction stir welding (fsw)
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Date
2018-05
Authors
Adha Fahmi Pauzi
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Abstract
Friction stir welding (FSW) is a relatively new joining process and has produced a big
impact on several industries due to many advantages over traditional welding process.
The present works aims investigate the feasibility of welding two pieces of aluminum
alloy (AA 6061) sheets of thickness 3mm by FSW process. This main objective of this
research is to study the effect on tensile strength, hardness and roughness with respect
to feed rate (welding speed), spindle speed (rotation speed), and tool angle and to
optimize the FSW parameters. Three level of feed rate i.e. at 31, 65, and 90 (mm/min),
spindle speed at 600, 865, and 1140 (rpm) and tool angle at 2, 3, 4 (°) were used in the
experiment. The fixture clamp fixed on the conventional milling machine has been
design and fabricate to enable this welding. FSW tools were designed and fabricated
from tool steel. In this study, tensile strength, hardness and roughness of FSW is
optimized using Taguchi L9 orthogonal design of experiments. The tensile and
hardness test were conducted to determine the mechanical properties of the weld and
roughness test were carried out to determine the surface roughness of the weld. The
hardness pattern was found to the lowest at the centre of the weld zone. The tool
shoulder depth plays the role on surface roughness. The optimum process parameters
were determined with reference to DoE performed. The spindle speed and feed rate are
the most significant parameters to the tensile strength of the weld.