Optimization of Process Parameters for Friction Stir Welding Of Aluminum Alloy AA6061 Using Square Pin Profile

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Short Title: Int. J. Mech. Eng. Robot. Res.
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Home > Articles > All Issues > 2014 > Volume 3, No. 2, April 2014 >

P Jagadeesh Chandra Prasad1 , P Hema2, and K Ravindranath3

1.M.Tech (Production Engg.) Student, Dept. of Mechanical Engineering, S.V.U.College of Engineering, Tirupati-517502.
2.Assistant Professor, Dept. of Mechanical Engineering, S.V.U.College of Engineering, Tirupati-517502.
Professor, Dept. of Mechanical Engineering, S.V.U.College of Engineering, Tirupati-517502.

Abstract— Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in aerospace, rail, automotive and marine industries for joining aluminium, magnesium, zinc and copper alloys. AA6061 aluminum alloy (Al-Mg-Si alloy) has gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to-weight ratio and good corrosion resistance. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. In present study, friction stir butt welds made of 6061 Al Alloys were performed with various welding parameters such as Tool Rotational Speed, Welding Speed and Axial Force using tool has Square Pin Profile. Experiment has been carried out on Twenty-Seven joints have been made on 6061 Al Alloy plates of 6.35 mm thick of same nature and tested for its Tensile, Impact and Hardness properties. Using ANOVA, influence of FSW Process Parameters is evaluated and optimum welding conditions for maximizing mechanical properties of the joint is determined. An Artificial Neural Network (ANN) model was developed for the analysis and a comparison was made between experimental and predicted data.

Index Terms— Friction Stir Welding, Aluminum Alloy, Tool Rotational Speed, Welding Speed, Axial Force, Tensile Strength, Impact Strength, Hardness, ANOVA, ANN

Cite: P Jagadeesh Chandra Prasad, P Hema, and K Ravindranath, " Optimization of Process Parameters for Friction Stir Welding Of Aluminum Alloy AA6061 Using Square Pin Profile," International Journal of Mechanical Engineering and Robotics Research, Vol. 3, No. 2, pp. 455-465, April 2014.