EX PERIMENTAL INVESTIGA TIONS OF TIG AND FRICTION STIR … · process parameters of FSW and TIG on the mechanical properties of tensile strength experiments conducted speed different

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International Journal of Mechanical Engineering and Technology (IJMET)Volume 8, Issue 7, JulyAvailable online at ISSN Print: 0976 © IAEME

EXAND FRICTION STIR WE

ABSTRACTAluminum alloys are welded using both tungsten inert gas (TIG) and friction stir

welding (FSW) and investigating on parental metal. solid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic atomic diffusion.an electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the process parameters of FSW and TIG on the mechanical properties of tensile strengthexperiments conductedspeeddifferent from the tungsten inert gas welded joint. The weld nugget consists of small grains in tensile strength gas welding. Hardness test of friction stir welding is more instead of tungsten inert gas welding where as in parental metal also.Key words:microstructure, weld nugget


International Journal of Mechanical Engineering and Technology (IJMET)Volume 8, Issue 7, JulyAvailable online at http://www.iaeme.com/IJMEISSN Print: 0976-6340 and ISSN Online: 0976

© IAEME Publication

EXPERIMENTAL INVESTIGAAND FRICTION STIR WE

Assistant Professor, MLR Institute


Associate Institute of Ae

AssistantVardhaman College of

ABSTRACT Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir

welding (FSW) and investigating on parental metal. solid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic atomic diffusion.an electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the process parameters of FSW and TIG on the mechanical properties of tensile strengthexperiments conductedspeed and feed.different from the tungsten inert gas welded joint. The weld nugget consists of small grains in tungsten inert gas weld tensile strength gas welding. Hardness test of friction stir welding is more instead of tungsten inert gas welding where as in parental metal also.Key words: microstructure, weld nugget

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International Journal of Mechanical Engineering and Technology (IJMET)Volume 8, Issue 7, July 2017, pp.

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Publication

PERIMENTAL INVESTIGAAND FRICTION STIR WE



Associate Professor, Institute of Aeron

ssistant Professor, Vardhaman College of

Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir welding (FSW) and investigating on parental metal. solid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic atomic diffusion. Tungsten Inert Gas welding process that usesan electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the process parameters of FSW and TIG on the mechanical properties of tensile strength test andexperiments conducted by

feed. The results indicate that the microstructure of the friction weld is different from the tungsten inert gas welded joint. The weld nugget consists of small

tungsten inert gas weld tensile strength of weld joint in friction stir welding is more instead of tungsten inert gas welding. Hardness test of friction stir welding is more instead of tungsten inert gas welding where as in parental metal also.

Aluminium alloy 7075, Friction Stir Welding, TIG welding, microstructure, weld nugget

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International Journal of Mechanical Engineering and Technology (IJMET)2017, pp. 290–297, Article ID: IJM

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Scopus Indexed

PERIMENTAL INVESTIGAAND FRICTION STIR WE

ASurya

Assistant Professor, DepartmentMLR Institute of Technology

BAssistant Professor, DepartmentMLR Institute of Technology

GVR SeshagiriraoProfessor, Departmentronautical Engineering,

Professor, Department of Vardhaman College of Engineering,

Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir welding (FSW) and investigating on parental metal. solid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic

Tungsten Inert Gas welding process that usesan electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the process parameters of FSW and TIG on the mechanical properties of

test and Vickers hardness, are considered for investigationby maintaining constant depth of penetration of weld

The results indicate that the microstructure of the friction weld is different from the tungsten inert gas welded joint. The weld nugget consists of small

tungsten inert gas weld and those are found inof weld joint in friction stir welding is more instead of tungsten inert

gas welding. Hardness test of friction stir welding is more instead of tungsten inert gas welding where as in parental metal also.

Aluminium alloy 7075, Friction Stir Welding, TIG welding, microstructure, weld nugget.

asp 290

International Journal of Mechanical Engineering and Technology (IJMET)Article ID: IJM

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Indexed

PERIMENTAL INVESTIGAAND FRICTION STIR WELDING PROCESS FOR

AA7075Surya Prakash

Department of of Technology, Hyderabad

B PrashanthDepartment of

of Technology, Hyderabad

GVR SeshagiriraoDepartment of

autical Engineering, Hyderaba

J Anoop Department of Engineering, Hyderabad

Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir welding (FSW) and investigating on parental metal. solid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic


Vickers hardness, are considered for investigationmaintaining constant depth of penetration of weld


and those are found inof weld joint in friction stir welding is more instead of tungsten inert

gas welding. Hardness test of friction stir welding is more instead of tungsten inert gas welding where as in parental metal also.

Aluminium alloy 7075, Friction Stir Welding, TIG welding,

International Journal of Mechanical Engineering and Technology (IJMET)Article ID: IJMET_08_07_034

asp?JType=IJME

PERIMENTAL INVESTIGATIONSLDING PROCESS FOR

A7075 Prakash

of Mechanical EngineeringHyderabad, Telangana, India

Prashanth of Mechanical Engineering

Hyderabad, Telangana, India

GVR Seshagirirao of Mechanical Engineering


Department of Mechanical Engineering


Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir welding (FSW) and investigating on parental metal. Frictionsolid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic




and those are found inof weld joint in friction stir welding is more instead of tungsten inert

gas welding. Hardness test of friction stir welding is more instead of tungsten inert


[email protected]

International Journal of Mechanical Engineering and Technology (IJMET) 07_034

asp?JType=IJMET&VType=8&IType=7

TIONSLDING PROCESS FOR

Mechanical Engineering, Telangana, India




Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir Friction Stir Welding (FSW) is a

solid state welding process in which the relative motion between the tool and the work piece produces heat which makes the material of two edges being joined by plastic

Tungsten Inert Gas welding process that uses the heat produced by an electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the process parameters of FSW and TIG on the mechanical properties of



and those are found in friction stir weldingof weld joint in friction stir welding is more instead of tungsten inert



[email protected]

T&VType=8&IType=7

TIONS OF TIG LDING PROCESS FOR

Mechanical Engineering , Telangana, India



Mechanical Engineering, , Telangana, India

Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir Stir Welding (FSW) is a


the heat produced by an electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the process parameters of FSW and TIG on the mechanical properties of the welds. The

Vickers hardness, are considered for investigationmaintaining constant depth of penetration of weld,


friction stir welding. The of weld joint in friction stir welding is more instead of tungsten inert



[email protected]

T&VType=8&IType=7

TIG LDING PROCESS FOR

Aluminum alloys are welded using both tungsten inert gas (TIG) and friction stir Stir Welding (FSW) is a


the heat produced by an electric arc created between non consumable tungsten electrode and the weld pool. In this project an attempt is made to compare and investigate the influence of the

the welds. The Vickers hardness, are considered for investigation of

tool The results indicate that the microstructure of the friction weld is

different from the tungsten inert gas welded joint. The weld nugget consists of small . The

of weld joint in friction stir welding is more instead of tungsten inert gas welding. Hardness test of friction stir welding is more instead of tungsten inert


Surya Prakash, B Prashanth, GVR Seshagirirao and J Anoop

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Cite this Article: Surya Prakash, B Prashanth, GVR Seshagirirao and J Anoop. Experimental Investigations of TIG and Friction Stir Welding Process for AA7075. International Journal of Mechanical Engineering and Technology, 8(7), 2017, pp. 290–297. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7

1. INTRODUCTION Welding is a fabrication process that joins materials by causing coalescence, usually done for metals or thermoplastics. This is generally done by melting the work pieces and adding a filler material to form a pool of molten material which cools down and develop into a tough bonding, with pressure at times used in conjunction with heat, or by itself, to produce the weld. This is in contrast with brazing and soldering process, which is done by melting a low-melting-point material and used to fill the gap of parent material pieces.

In late 1991 a very novel and potentially world beating welding method was conceived at The Welding Institute(TWI). The process was named as friction stir welding (FSW), and TWI filed for world-wide patent[1]. Consistent with the more conventional methods of friction welding, which have been practiced since the early 1950s, the weld is made in the solid phase, that is, no melting is involved. FSW uses a rotating tool to generate the necessary heat for the process. Since its invention, the process has received world-wide attention and today two Scandinavian companies are using the technology in production, particularly for joining aluminium alloys. Also, FSW is a process that can be automated. It is also a cleaner and more efficient process compared to conventional techniques FSW process can be used with different alloy materials, aluminium either as parent material or alloy material. Few researchers studied the optimization of machining parameters on Ti-6Al-4V material by using hgh speed machining process which is a base process for Friction stir welding[2,3]. Gurmeet sing et. al. found that friction stir welded joints have superior mechanical properties as compared to TIG welded joints. From the micro structure analysis it was observed that fine and equiaxed grains were observed in the friction stir welded joints and coarse grains were observed in TIG welded joints[4]. The process can also be experimented in manufacturing of cryogenic vessels[5].

2. WELDING PROCESSES

2.1. Friction Stir Welding Process

2.1.1. Working Principle In friction stir welding (FSW) a cylindrical, shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two pieces butted together. The parts have to be clamped together in contact onto a backing plate to prevent the abutting joint faces from being forced apart. Frictional heat is generated between the work piece material and welding tool which has a property of wear resistant. This heat produced by the friction causes the latter material to soften without reaching the melting point of the parent material and allows traversing of the tool along the weld line. The maximum temperature reached is of the order of 0.8 of the melting temperature of the material. The plasticized material is transferred from leading edge of the tool probe to the trailing edge and is forged by the intimate contact of the pin profile and the tool shoulder. It leaves a solid phase bond between the two pieces[6,7]. The vertical milling machine used for the experiment shown in figure 1.


2.1.2. Process FSW involves complex material movement and plastic deformation. geometry and wover materialadvancementare addressed Friction stir welded material1. Feed rate 2. Spindle speed3. Depth of penetration

2.1.3. Welding For FSW, two parameters are very important: of joint and rotationthe toolfinishes welding process. higher friction hefrictional coupling of tool surface with work piece heat. So, a monotonic increase in heating with increasing tool rotation rate is notthe coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.Typical friction stir welding setup is shown in figur

Experimental Investigations of TIG and Friction


Process ParametersFSW involves complex material movement and plastic deformation. geometry and welding parametersover material andadvancement of material. In this section, a few major factors affectingare addressed such as Friction stir welded material

Feed rate Spindle speed

3. Depth of penetration

Welding ParametersFor FSW, two parameters are very important: of joint and tool rotation rate (v, rpm) in clockwise orrotation of the toolthe tool translationfinishes welding process. higher friction heating and result in more frictional coupling of tool surface with work piece

. So, a monotonic increase in heating with increasing tool rotation rate is notthe coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.Typical friction stir welding setup is shown in figur



arameters FSW involves complex material movement and plastic deformation.

elding parametersand flow pattern

of material. In this section, a few major factors affectingsuch as joint design,

Friction stir welded material depends on the following three process parameters. They are

3. Depth of penetration

arameters For FSW, two parameters are very important:

tool rotation rate (v, rpm) in clockwise orof the tool results in stirring and translation moves the

finishes welding process. If tool rotationating and result in more

frictional coupling of tool surface with work piece . So, a monotonic increase in heating with increasing tool rotation rate is not

the coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.Typical friction stir welding setup is shown in figur


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Figure 1 Vertical milling machine

FSW involves complex material movement and plastic deformation. elding parameters exert

flow pattern of the materialof material. In this section, a few major factors affecting

joint design, tool geometrydepends on the following three process parameters. They are

For FSW, two parameters are very important: tool rotation rate (v, rpm) in clockwise or

results in stirring and moves the plasticized

tool rotation ating and result in more

frictional coupling of tool surface with work piece . So, a monotonic increase in heating with increasing tool rotation rate is not

the coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.Typical friction stir welding setup is shown in figur


asp 292

Vertical milling machine

FSW involves complex material movement and plastic deformation. exert considerable

of the material, thereby influencing the micro structural of material. In this section, a few major factors affecting

tool geometry anddepends on the following three process parameters. They are

For FSW, two parameters are very important: tool traverse speed (n, mm/min) along the line tool rotation rate (v, rpm) in clockwise or

results in stirring and integrationplasticized material from the front to the back of the pin and

is higher, it ating and result in more severe stirring and mixing of mat

frictional coupling of tool surface with work piece will play an eminent role of. So, a monotonic increase in heating with increasing tool rotation rate is not

the coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.Typical friction stir welding setup is shown in figure 2.

Experimental Investigations of TIG and Friction Stir Welding Process for AA7075

Vertical milling machine

FSW involves complex material movement and plastic deformation. considerable effect on distribution

, thereby influencing the micro structural of material. In this section, a few major factors affecting

and welding parameters. The sdepends on the following three process parameters. They are

tool traverse speed (n, mm/min) along the line tool rotation rate (v, rpm) in clockwise or counter clockwise direction

ration of material around the rotating pin and material from the front to the back of the pin and

it generates stirring and mixing of mat

will play an eminent role of. So, a monotonic increase in heating with increasing tool rotation rate is not

the coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.

e 2.

Stir Welding Process for AA7075

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FSW involves complex material movement and plastic deformation. effect on distribution

, thereby influencing the micro structural of material. In this section, a few major factors affecting FSW

welding parameters. The sdepends on the following three process parameters. They are

tool traverse speed (n, mm/min) along the line counter clockwise direction

of material around the rotating pin and material from the front to the back of the pin and

higher temperature because of stirring and mixing of mat

will play an eminent role of. So, a monotonic increase in heating with increasing tool rotation rate is not



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FSW involves complex material movement and plastic deformation. Joint designeffect on distribution of temperature

, thereby influencing the micro structural FSW process,

welding parameters. The strength of depends on the following three process parameters. They are

tool traverse speed (n, mm/min) along the line counter clockwise direction


higher temperature because of stirring and mixing of material. However,

will play an eminent role of govern. So, a monotonic increase in heating with increasing tool rotation rate is not expected as



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Joint design, tool of temperature

, thereby influencing the micro structural process, which

trength of depends on the following three process parameters. They are

tool traverse speed (n, mm/min) along the line counter clockwise direction. The


higher temperature because of . However, the governing the

expected as the coefficient of friction at interface will change with increasing tool rotation rate. The ratio of influence of tool speed and weld speed is 4: 3 which was found by experimental results.


2.2. TIG Welding

2.2.1. WorkingTIG welding is a welding process that uses a power source, a shielding gas and a TIG hand piece. The power is fed out of the power source, down the TIG hand piece and is delivered to a tungstenwork piecesurrounding temperatures up to 19,400 is shown in the figure 3.

3. EXPERIMENTAL SETU

3.1. Friction Stir WeldingA vertical milling machine was used for friction stir alloy. The machine used has a maximum speed of 2000 rpm and 10was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole, which will facilitate the startand travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20


TIG Welding

Working PrincipleTIG welding is a welding process that uses a power source, a shielding gas and a TIG hand piece. The power is fed out of the power source, down the TIG hand piece and is delivered to a tungsten electrode which is fitted into the hanwork piece and tungsten electrode. The surrounding atmospheretemperatures up to 19,400 is shown in the figure 3.


Friction Stir WeldingA vertical milling machine was used for friction stir alloy. The machine used has a maximum speed of 2000 rpm and 10was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole, which will facilitate the startand travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20



TIG Welding

rinciple TIG welding is a welding process that uses a power source, a shielding gas and a TIG hand piece. The power is fed out of the power source, down the TIG hand piece and is delivered to

electrode which is fitted into the hanand tungsten electrode. The atmosphere by a gas shield

temperatures up to 19,400 oC and this heat can be veryis shown in the figure 3.


Friction Stir Welding A vertical milling machine was used for friction stir alloy. The machine used has a maximum speed of 2000 rpm and 10was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole, which will facilitate the start-and travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20


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Figure

TIG welding is a welding process that uses a power source, a shielding gas and a TIG hand piece. The power is fed out of the power source, down the TIG hand piece and is delivered to

electrode which is fitted into the hanand tungsten electrode. The

by a gas shield C and this heat can be very

Figure

3. EXPERIMENTAL SETUP

A vertical milling machine was used for friction stir alloy. The machine used has a maximum speed of 2000 rpm and 10was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole,

-up of welding. Processing began at spindle speed of 800 rpm and travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20


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ure 2 FSW setup


electrode which is fitted into the hand piece. An electric arc isand tungsten electrode. The welding zone

by a gas shield i.e., inert gas. The electric arc can prodC and this heat can be very

3 TIG welding setup

A vertical milling machine was used for friction stir alloy. The machine used has a maximum speed of 2000 rpm and 10was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole,

of welding. Processing began at spindle speed of 800 rpm and travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20


FSW setup


d piece. An electric arc iswelding zone and electrode

inert gas. The electric arc can prodC and this heat can be very focused local heat

TIG welding setup

A vertical milling machine was used for friction stir welding (FSW) of Aluminium AA 7075 alloy. The machine used has a maximum speed of 2000 rpm and 10was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole,



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d piece. An electric arc is created beand electrode is protected from the

inert gas. The electric arc can prodfocused local heat.

welding (FSW) of Aluminium AA 7075 alloy. The machine used has a maximum speed of 2000 rpm and 10-horse power. Test piece was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole,



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created between theis protected from the

inert gas. The electric arc can prod. TIG welding setup

welding (FSW) of Aluminium AA 7075 horse power. Test piece

was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole, of welding. Processing began at spindle speed of 800 rpm

and travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20

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tween the is protected from the

inert gas. The electric arc can produce TIG welding setup

welding (FSW) of Aluminium AA 7075 horse power. Test piece

was clamped in the fixture tightly. Initially the rotating pin was inserted into a predrilled hole, of welding. Processing began at spindle speed of 800 rpm

and travel rate of 18 inch/min. The speed was increased to 1000rpm and feed rate to 20


inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the result was one sideto mechanical testing. In the present work the influence of speed, feed on the performance of FSW such as Hardness test, tensile strength and micro structure properties.

3.2. TIGIn this experiment, an aluminium platematerialand grinding joined. Later any external material on the surfacepaper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed. in the welding areazirconiated tungstdiameter to 2/3 of the original diameter by grinding and then striking an arc on a scrap material piece. This creates a ball on the end of the electrode. Generally an electrode that is too small for the welding current will form aElectrode will not form a satisfactory ball at all. before performing actual experimentcould be possible and no o

4. RESULTS & DISCUSSION

4.1. Tensile After conducting friction stir welding and TIG welding on the aluminium alloy 7075, the materials were cut as per ASTM standards and performed tensilewelding processand 2.



inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the result was one sideto mechanical testing. In the present work the influence of speed, feed on the performance of FSW such as Hardness test, tensile strength and micro structure properties.

TIG WeldingIn this experiment, an aluminium platematerial. This plate was cut with dimensionand grinding process has been performed onjoined. Later any external material on the surfacepaper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed. in the welding areairconiated tungsten electrodes

diameter to 2/3 of the original diameter by grinding and then striking an arc on a scrap material piece. This creates a ball on the end of the electrode. Generally an electrode that is too small for the welding current will form aElectrode will not form a satisfactory ball at all. before performing actual experiment

be possible and no o

RESULTS & DISCUSSION

Tensile Test After conducting friction stir welding and TIG welding on the aluminium alloy 7075, the materials were cut as per ASTM standards and performed tensilewelding process. The tensile test results of both welding processes are mentioned in Table 1

Sl.no Ultimate load (

1 2 3



inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the result was one side welded platesto mechanical testing. In the present work the influence of speed, feed on the performance of FSW such as Hardness test, tensile strength and micro structure properties.

Fig

Welding In this experiment, an aluminium plate

plate was cut with dimensionprocess has been performed on

joined. Later any external material on the surfacepaper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed. in the welding area, TIG welding with AC current was used to conduct the experiments with

en electrodesdiameter to 2/3 of the original diameter by grinding and then striking an arc on a scrap material piece. This creates a ball on the end of the electrode. Generally an electrode that is too small for the welding current will form aElectrode will not form a satisfactory ball at all. before performing actual experiment

be possible and no observable d


After conducting friction stir welding and TIG welding on the aluminium alloy 7075, the materials were cut as per ASTM standards and performed tensile

The tensile test results of both welding processes are mentioned in Table 1

Table 1

Ultimate load (

9.0008.6008.400


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inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the welded plates which is shown in figure 4

to mechanical testing. In the present work the influence of speed, feed on the performance of FSW such as Hardness test, tensile strength and micro structure properties.

Figure 4 Friction stir Welding process

In this experiment, an aluminium plateplate was cut with dimensionprocess has been performed on

joined. Later any external material on the surfacepaper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed.

, TIG welding with AC current was used to conduct the experiments with en electrodes. The end of the electrode was pre

diameter to 2/3 of the original diameter by grinding and then striking an arc on a scrap material piece. This creates a ball on the end of the electrode. Generally an electrode that is too small for the welding current will form aElectrode will not form a satisfactory ball at all. before performing actual experiment to get the appropriate parameter range where welding

bservable defects




1 Tensile test report on friction stir welding

Ultimate load (Kn)

9.000 8.600 8.400


asp 294

inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the which is shown in figure 4


Friction stir Welding process

In this experiment, an aluminium plate thicknessplate was cut with dimensions of 120 mm x 50 mm with the help of bandprocess has been performed on the edge

joined. Later any external material on the surfacepaper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed.

, TIG welding with AC current was used to conduct the experiments with . The end of the electrode was pre

diameter to 2/3 of the original diameter by grinding and then striking an arc on a scrap material piece. This creates a ball on the end of the electrode. Generally an electrode that is too small for the welding current will form an excessively large ball, whereas too large an Electrode will not form a satisfactory ball at all. Few

to get the appropriate parameter range where welding efects were occurred



Tensile test report on friction stir weldingUltimate tensile

strength (N/154.962144.854148.096


inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the which is shown in figure 4. The plates where then subjected



thickness of 3 mm was selected as workof 120 mm x 50 mm with the help of bandthe edges to smooth the surface

joined. Later any external material on the surfaces are removed by polishing withpaper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed.

, TIG welding with AC current was used to conduct the experiments with . The end of the electrode was pre

diameter to 2/3 of the original diameter by grinding and then striking an arc on a scrap material piece. This creates a ball on the end of the electrode. Generally an electrode that is

n excessively large ball, whereas too large an Few trial experiments have been performed

to get the appropriate parameter range where welding occurred like under



Tensile test report on friction stir weldingUltimate tensile

strength (N/mm2) 154.962 144.854 148.096


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inch/min. Since tool plunge was to the extent of 2.7 mm and plate thickness being 3 mm, the . The plates where then subjected



3 mm was selected as workof 120 mm x 50 mm with the help of band

to smooth the surface removed by polishing with

paper. After sample preparation, Aluminium plates are fixed in the working table with fleclamp side by side and welding done so that a butt join can be formed. To concentrate

, TIG welding with AC current was used to conduct the experiments with . The end of the electrode was prepared by reducing the tip


n excessively large ball, whereas too large an trial experiments have been performed

to get the appropriate parameter range where welding like undercutting and porosity

After conducting friction stir welding and TIG welding on the aluminium alloy 7075, the materials were cut as per ASTM standards and performed tensile tests on 3 specimens of each


Tensile test report on friction stir welding

Elongation (%)

9.6808.7208.860


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3 mm was selected as workof 120 mm x 50 mm with the help of band

to smooth the surface which are to be removed by polishing with

paper. After sample preparation, Aluminium plates are fixed in the working table with fleTo concentrate

, TIG welding with AC current was used to conduct the experiments with pared by reducing the tip



to get the appropriate parameter range where welding cutting and porosity

After conducting friction stir welding and TIG welding on the aluminium alloy 7075, the tests on 3 specimens of each


Elongation (%)

9.680 8.720 8.860


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to mechanical testing. In the present work the influence of speed, feed on the performance of

3 mm was selected as work piece of 120 mm x 50 mm with the help of band-saw

which are to be removed by polishing with emery

paper. After sample preparation, Aluminium plates are fixed in the working table with flexible the heat

, TIG welding with AC current was used to conduct the experiments with pared by reducing the tip



to get the appropriate parameter range where welding cutting and porosity.

After conducting friction stir welding and TIG welding on the aluminium alloy 7075, the tests on 3 specimens of each



4.2. Vickers After conducting friction stir welding and TIG welding on the aluminium alloy 7075, performed Vickers along with the parent material before performing weldingwelding processes are mentioned in Table 3 and 4 and parent material in Table 5.

S

S

S

4.3. Microstructure

4.3.1. Microstructure of FSW The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particlesprecipitand observed that the heat affected zone(HAZ) is well fused and free from nonmetallic defects.


Sl.No. Ultimate load (K

1 2 3

Vickers Hardness After conducting friction stir welding and TIG welding on the aluminium alloy 7075, performed Vickers along with the parent material before performing weldingwelding processes are mentioned in Table 3 and 4 and parent material in Table 5.

S.No Location

1 On weld

S.No Location

1 On weld

S.No Location

1 On random point

Microstructure

Microstructure of FSW The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particlesprecipitated which and observed that the heat affected zone(HAZ) is well fused and free from nonmetallic defects. These results can be seen in Figure 5.



Table

Ultimate load (K

3.4003.0003.600

ardness TestAfter conducting friction stir welding and TIG welding on the aluminium alloy 7075, performed Vickers hardness test on welded zone ofalong with the parent material before performing weldingwelding processes are mentioned in Table 3 and 4 and parent material in Table 5.

Table 3 Hardness test report on friction stir weld

Location On weld

zone

Table 4

Location On weld

zone

Table 5

Location Impression1On random

point

Microstructure

Microstructure of FSW The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles

are Cu-Al2, Mg2Si with some inter metallic. The microstructure is studied and observed that the heat affected zone(HAZ) is well fused and free from nonmetallic

These results can be seen in Figure 5.

Figure


IJMET/index.asp

Table 2 Tensile test report on TIG

Ultimate load (Kn)

3.400 3.000 3.600

est After conducting friction stir welding and TIG welding on the aluminium alloy 7075,

hardness test on welded zone ofalong with the parent material before performing weldingwelding processes are mentioned in Table 3 and 4 and parent material in Table 5.

Hardness test report on friction stir weld

Impression1

114

Table 4 Hardness test report on TIG welded zone

Impression1

109

Table 5 Hardness test report on parent metal

Impression1

109

Microstructure of FSW Material The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles

Al2, Mg2Si with some inter metallic. The microstructure is studied and observed that the heat affected zone(HAZ) is well fused and free from nonmetallic


ure 5 Micro structure reports of FSW material


asp 295

Tensile test report on TIG

Ultimate tensile strength (N/

60.64951.86761.760

After conducting friction stir welding and TIG welding on the aluminium alloy 7075, hardness test on welded zone of

along with the parent material before performing weldingwelding processes are mentioned in Table 3 and 4 and parent material in Table 5.


Impression1 Impression2

113

dness test report on TIG welded zone


109

ardness test report on parent metal


110

The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles



structure reports of FSW material


Tensile test report on TIG welding

Ultimate tensile strength (N/mm2)

60.649 51.867 61.760

After conducting friction stir welding and TIG welding on the aluminium alloy 7075, hardness test on welded zone of 3 specimens of each welding process

along with the parent material before performing welding. The hardness test results of both welding processes are mentioned in Table 3 and 4 and parent material in Table 5.



113



109



110





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welding

Elongation (%)

2.4402.262.300

After conducting friction stir welding and TIG welding on the aluminium alloy 7075, 3 specimens of each welding process

he hardness test results of both welding processes are mentioned in Table 3 and 4 and parent material in Table 5.

Hardness test report on friction stir welded zone

Impression3

113


Impression3

110


Impression3

111





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Elongation (%)

2.440 2.26 2.300


he hardness test results of both welding processes are mentioned in Table 3 and 4 and parent material in Table 5.

Average

113.33

Average

109.33

Average

110

The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely


[email protected]


he hardness test results of both

Average

verage

verage

The parent metal shows fine grains of the eutectic particles that are precipitated uniformly in the aluminum solid solution. The microstructure shows the dense grain flow along the

completely Al2, Mg2Si with some inter metallic. The microstructure is studied

and observed that the heat affected zone(HAZ) is well fused and free from nonmetallic


4.3.2. Microstructure of TIG The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated Cu-Al2, Mgprecipitated and fragmented eutectic particles from both the mechanical transformed zone. This point is just fraction of zone. This can also be called heat affected zone

5. CONCLUSIONThe following conclusions can be drawn based on the results of the present experimental investigations on

Smooth surface finish can be obtained by using Friction stir welding with a tool havingsmooth pin.

The microstructure is studied and observed that the heat affected zonefree from nonmetallic defects.

Here in Friction stir welding the breaking point is outside the weld on tensile test. where as in TIG welding the br

Here in hardness test on weldwhen compared with TIG welded materialwelding and TIG parent metal is we

No cracking occurred in the heat affected zone

ACKNOWLEDGEMENTSThe authors thank Dr.College of EngineeringMLR Institute of Technology

REFERENCES[1]

[2]



Microstructure of TIG The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated

, Mg2Si with some intermetallic.precipitated and fragmented eutectic particles from both the mechanical transformed zone. This point is just fraction of zone. This can also be called heat affected zone

CONCLUSIONThe following conclusions can be drawn based on the results of the present experimental investigations on welding

Smooth surface finish can be obtained by using Friction stir welding with a tool havingsmooth pin.


Here in Friction stir welding the breaking point is outside the weld on tensile test. where as in TIG welding the br



ACKNOWLEDGEMENTSThe authors thank Dr.College of EngineeringMLR Institute of Technology

REFERENCES FSSW-lean,mean

Link W

Venkata RTurning Innovative Technology and Creative Engineering, May 2011 Issue Vol.1 No.521(12)



Microstructure of TIG The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated

Si with some intermetallic.precipitated and fragmented eutectic particles from both the mechanical transformed zone. This point is just fraction of zone. This can also be called heat affected zone

Figure 6

CONCLUSIONS The following conclusions can be drawn based on the results of the present experimental

welding the AluminiumSmooth surface finish can be obtained by using Friction stir welding with a tool having


Here in Friction stir welding the breaking point is outside the weld on tensile test. where as in TIG welding the breaking point is exactly on the weld.



ACKNOWLEDGEMENTSThe authors thank Dr. M.Sreenivasa RaoCollege of Engineering, Hyderabad. Also weMLR Institute of Technology,

REFERENCES lean,mean and 227 westmound, Wi 53186.

Venkata Ramana, MTurning of Ti-6Al-4VInnovative Technology and Creative Engineering, May 2011 Issue Vol.1 No.5


IJMET/index.asp

Microstructure of TIG Welded MaterialThe microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated

Si with some intermetallic.precipitated and fragmented eutectic particles from both the mechanical transformed zone. This point is just fraction of zone. This can also be called heat affected zone

Microstructure reports of TIG welded material

The following conclusions can be drawn based on the results of the present experimental Aluminium

Smooth surface finish can be obtained by using Friction stir welding with a tool having


Here in Friction stir welding the breaking point is outside the weld on tensile test. where as in eaking point is exactly on the weld.

Here in hardness test on weld which has shown fwhen compared with TIG welded materialwelding and TIG parent metal is weak compared to hardness test on weld.


ACKNOWLEDGEMENTS M.Sreenivasa Rao

Hyderabad. Also we, Hyderabad as well as

and green Authors:227 westmound, Wi 53186.

M. Srinivasulu4V Alloy under different Cooling Conditions

Innovative Technology and Creative Engineering, May 2011 Issue Vol.1 No.5


asp 296

aterial The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated

Si with some intermetallic. It is observed that tprecipitated and fragmented eutectic particles from both the mechanical transformed zone. This point is just fraction of zone. This can also be called heat affected zone.


The following conclusions can be drawn based on the results of the present experimental Aluminium alloy using two different processes


The microstructure is studied and observed that the heat affected zone


which has shown fwhen compared with TIG welded material. Where as in parent metal also in both Friction stir

ak compared to hardness test on weld.

No cracking occurred in the heat affected zone.

M.Sreenivasa Rao, ProfessorHyderabad. Also we also

Hyderabad as well as

Authors: C.B. 227 westmound, Wi 53186.

Srinivasulu, K. Krishna Mohana Raounder different Cooling Conditions



The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated

It is observed that tprecipitated and fragmented eutectic particles from both the bars, and also shows the thermomechanical transformed zone. This point is just fraction of distance


The following conclusions can be drawn based on the results of the present experimental using two different processes


The microstructure is studied and observed that the heat affected zone


which has shown friction stir welded material is more stronger . Where as in parent metal also in both Friction stir


Professor for the extended facilities in thank Dr. S. Ma his able guidance in this work.

C.B. smith, J.F. Hrnrichs,

Krishna Mohana Raounder different Cooling Conditions



[email protected]

The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated

It is observed that the weld zone shows the fine bars, and also shows the thermo

distance from the friction weld


The following conclusions can be drawn based on the results of the present experimental using two different processes


The microstructure is studied and observed that the heat affected zone (HAZ) is well fused and

Here in Friction stir welding the breaking point is outside the weld on tensile test. where as in

stir welded material is more stronger . Where as in parent metal also in both Friction stir


for the extended facilities in thank Dr. S. Madhu

able guidance in this work.

Hrnrichs, P.C.Ruehl Friction

Krishna Mohana Rao, G., "Optimunder different Cooling Conditions”, International Journal of



[email protected]

The microstructure shows the dense grain flow along the direction of the force. The heat of the process made the eutectic particles completely precipitated. The precipitated particles are

he weld zone shows the fine bars, and also shows the thermo

from the friction weld

The following conclusions can be drawn based on the results of the present experimental using two different processes are:


(HAZ) is well fused and




for the extended facilities in for the facilities in

able guidance in this work.

P.C.Ruehl Friction

"Optimal ParametersInternational Journal of



[email protected]

The microstructure shows the dense grain flow along the direction of the force. The heat of particles are

he weld zone shows the fine bars, and also shows the thermo-

from the friction weld

The following conclusions can be drawn based on the results of the present experimental

Smooth surface finish can be obtained by using Friction stir welding with a tool having a

(HAZ) is well fused and



for the extended facilities in JNTUH facilities in

P.C.Ruehl Friction stir

Parameters in International Journal of

Innovative Technology and Creative Engineering, May 2011 Issue Vol.1 No.5, pp. 10-


http://www.iaeme.com/IJMET/index.asp 297 [email protected]

[3] B. Prashanth and J. Krishnaraj, Optimization of Surface Roughness of Ti-6al-4v Titanium Alloy Using Taguchi Technique, International Journal of Civil Engineering and Technology, 8(7), 2017, pp. 115–121.

[4] Singh, Gurmeet, et al. "Experimental comparison of friction stir welding process and TIG welding process for 6082-T6 Aluminium alloy." Materials Today: Proceedings 4.2 (2017): 3590-3600.

[5] Krishnaraj, J. and Prashanth, B. A Comprehensive Study on Various Welding Techniques Used for Cryogenic Vessels. "International Journal of Civil Engineering & Technology (IJCIET), Volume 8, Issue 6, June 2017, pp. 171–177

[6] R.Arokiadass , K.Palaniradja and N.Alagumoorthi, (2011), “Surface Roughness Preciction model in end milling of AL/Sicp MMC, International Journal of engineering science and technology,Vol. 03, pp. 78-87

[7] Naidu, Gollu, and M. Murali Krishna. "Investigation on the Change Effected By the Tool Type on the Hardness of Friction Stir Processed By Copper." IJITR 5.3 (2017): 6486-6491.

[8] P. Gopu and M. Dev anand Experimental Investigation on Friction Stir Welding Process Using ANFIS Model. International Journal of Mechanical Engineering and Technology, 8(5), 2017, pp. 886–895.

[9] N Ravinder Reddy and G Mohan Reddy, Friction Stir Welding of Aluminium Alloys-A Review, International Journal of Mechanical Engineering and Technology, 7(2), 2016, pp. 73–80.

EX PERIMENTAL INVESTIGA TIONS OF TIG AND FRICTION STIR … · process parameters of FSW and TIG on the mechanical properties of tensile strength experiments conducted speed different

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