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Computational Analysis And Experimental Investigations On The Influence Of The FSW Tool Pin Profiles Towards Superior IMC In Aluminum Alloys

J. Kandasamy*, M. Manzoor Hussain**, S. Rajesham***

* Assistant Professor, Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, R.R.District.

** Professor, Department of Mechanical Engineering, College of Engineering, JNTUH, Kukatpally, Hyderabad.

*** Principal, Pulla Reddy Institute of Technology, Wargal, Medak District, Andhrapradesh, India.

Periodicity:February - April'2012
DOI : https://doi.org/10.26634/jme.2.2.1564

Abstract

Friction Stir Welding (FSW) has several benefits in welding “difficult to weld” aluminium alloys and dissimilar materials. FSW requires careful selection of process parameters (mainly the tool geometry, tool rotational speed, welding speed and the axial downward force) in order to make a defect free weld joint. The tool geometry is the most influential aspect of process development. It plays a vital role in material flow towards joint consolidation, as the weld microstructure varies with the tool pin design. The paper attempts to establish the pin profile geometry that develops low stress in the tool and weld joint and thereby simultaneously enhancing the plastic flow of the metal to maximize the weld strength by forming a superior Inter Metallic Compound (IMC) in the weld zone. FSW tools with various pin profiles are designed based on theories of failures. Modeling and computational analysis were performed on the basic profiles pf the pin geometry. Results indicate that the resistance force exerted by the cylindrical shape pin profile is high and the stress induced is less in the weld joint as compared to other type of profiles. Experimental analysis performed on AA7075 alloys reveals that maximum weld strength and sound metallurgical properties is observed in the joint produced by the cylindrical pin under optimum weld conditions due to uniform material flow throughout the weld cross section.

Keywords

Weld strength, Tool design, IMC, Pin profiles, ANSYS, Weld properties.

How to Cite this Article?

J Kandasamy, M Manzoor Hussain and S Rajesham (2012). Computational Analysis And Experimental Investigations On The Influence Of The FSW Tool Pin Profiles Towards Superior IMC In Aluminum Alloys. i-manager’s Journal on Mechanical Engineering, 2(2), 7-12. https://doi.org/10.26634/jme.2.2.1564

References

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Computational Analysis And Experimental Investigations On The Influence Of The FSW Tool Pin Profiles Towards Superior IMC In Aluminum Alloys

Abstract

Keywords

How to Cite this Article?

References

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