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http://www.iaeme.com/IJMET/index.asp 1629 [email protected] International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 8, August 2017, pp. 16291641, Article ID: IJMET_08_08_177 Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed EXPERIMENTAL INVESTIGATION ON FRICTION STIR WELDED ALUMINIUM SCILICON ALLOY S. Thirumavalavan Assistant Professor, Department of Mechanical Engineering, Bharath University, Chennai, Tamilnadu, India R. Sabarish Assistant Professor, Department of Mechanical Engineering, Bharath University, Chennai, Tamilnadu, India U. Ganesan Assistant Professor, Department of Mechanical Engineering, Jawahar Engineering College, Chennai, Tamilnadu, India ABSTRACT Friction Stir Welding has been recognized as a potential candidate for joining of non-ferrous materials which found its application in transportation, automobile, ship building and aerospace industries. The aim of the present study is to investigate the flow of material around different tool pin profiles. Tensile strength tests and hardness tests are to be carried out on aluminium silicon alloy to determine the mechanical properties of weld. The flow of the material around the pin can be determined by tracing the flow lines. The Tensile failure characteristics of the weld are to be discussed. The friction stir welding is done on AA6082 alloy, an Al-Mg-Si alloy. A few of silicon particles remain as such in the aluminium matrix and the remaining forms Mg 2 Si compounds. The Mg 2 Si compounds can be clearly seen as a black phase when viewed under optical microscope. During FSW, coarse grains get refined into finer grains and get deposited in the stir zone. Morphology, Size and Shape variation of grains are helpful in classifying the various zones of friction stir welding. Friction stir welding of aluminium is widely applied in marine, aerospace, rail, automotive and some other transportation industries. Friction Stir Welding of AA6082 Key words: silicon alloy, Friction stir welding, CNC Lathe, fabrication. Cite this Article: S. Thirumavalavan, R. Sabarish, U. Ganesan, Experimental Investigation on Friction Stir Welded AluminiumScilicon Alloy, International Journal of Mechanical Engineering and Technology 8(8), 2017, pp. 16291641. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8
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Page 1: EXPERIMENTAL INVESTIGATION ON FRICTION STIR WELDED ... · Friction stir welding of aluminium is widely applied in marine, aerospace, rail, automotive and some other transportation

http://www.iaeme.com/IJMET/index.asp 1629 [email protected]

International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 8, August 2017, pp. 1629–1641, Article ID: IJMET_08_08_177

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

EXPERIMENTAL INVESTIGATION ON

FRICTION STIR WELDED ALUMINIUM

–SCILICON ALLOY

S. Thirumavalavan

Assistant Professor, Department of Mechanical Engineering,

Bharath University, Chennai, Tamilnadu, India

R. Sabarish

Assistant Professor, Department of Mechanical Engineering,

Bharath University, Chennai, Tamilnadu, India

U. Ganesan

Assistant Professor, Department of Mechanical Engineering,

Jawahar Engineering College, Chennai, Tamilnadu, India

ABSTRACT

Friction Stir Welding has been recognized as a potential candidate for joining of

non-ferrous materials which found its application in transportation, automobile, ship

building and aerospace industries. The aim of the present study is to investigate the

flow of material around different tool pin profiles. Tensile strength tests and hardness

tests are to be carried out on aluminium – silicon alloy to determine the mechanical

properties of weld. The flow of the material around the pin can be determined by

tracing the flow lines. The Tensile failure characteristics of the weld are to be

discussed.

The friction stir welding is done on AA6082 alloy, an Al-Mg-Si alloy. A few of

silicon particles remain as such in the aluminium matrix and the remaining forms

Mg2Si compounds. The Mg2Si compounds can be clearly seen as a black phase when

viewed under optical microscope. During FSW, coarse grains get refined into finer

grains and get deposited in the stir zone. Morphology, Size and Shape variation of

grains are helpful in classifying the various zones of friction stir welding.

Friction stir welding of aluminium is widely applied in marine, aerospace, rail,

automotive and some other transportation industries. Friction Stir Welding of AA6082

Key words: silicon alloy, Friction stir welding, CNC Lathe, fabrication.

Cite this Article: S. Thirumavalavan, R. Sabarish, U. Ganesan, Experimental

Investigation on Friction Stir Welded Aluminium–Scilicon Alloy, International

Journal of Mechanical Engineering and Technology 8(8), 2017, pp. 1629–1641.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

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S. Thirumavalavan, R. Sabarish, U. Ganesan

http://www.iaeme.com/IJMET/index.asp 1630 [email protected]

1. INTRODUCTION

1.1. Need for Study

The need for study is to understand the complete process of friction stir welding; the forces

involved in welding the material; defects caused during friction stir welding; and process

parameters involved. This study has given a clear idea about the FSW process behaviour,

setup and procedure of welding. Both mechanical and microstructural tests which were done

on the specimen and its principle of operation was also studied.

1.2. Objective of the Project

The main objective of the project is to friction stir weld the Al-Si alloy using a conventional

Vertical Milling machine; to carry out the microstructural investigation in Optical Microscope

and to determine the flow of material around the tool pin profile by interpreting the

microstructural analysis data; to conduct mechanical tests on the specimen (Tensile Test and

Micro-Vickers Hardness Test) to establish the mechanically sound weld and to report

microstructurally and mechanically optimal weld.

2. MATERIAL SELECTION

2.1. Plate Material

The main aim of the project work is the microstructural investigation i.e., analysing the

microstructures at various zones of FSW. Classifying various region of FSW is a tedious

process. It requires a deep knowledge in material science[1-5].

In case of pure aluminium or Al alloys with same microstructure, this investigation

becomes much tougher. In such cases, the presence of second phase additives will act as

medium to classify the various zones of FSW.

2.2. Silicon

Silicon was chosen as a second phase additive in this project. Silicon is naturally added to the

Aluminium alloys to improve their strength. Silicon remains dispersed in the aluminium

matrix without undergoing any atomic level interaction.

Silicon is a high thermal conductivity material and also it is cheap. These advantages

make silicon a preferable additive in aluminium alloys.

But the main problem with the Silicon is that it is a brittle material. Excessive Silicon in

the material turns a ductile material into a brittle one. So that in almost all aluminium alloys

Silicon content is kept in very low percentages. Figure 1 shows the lump of silicon

powders[6-9].

Figure 1 Silicon powders

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Experimental Investigation on Friction Stir Welded Aluminium–Scilicon Alloy

http://www.iaeme.com/IJMET/index.asp 1631 [email protected]

This property of silicon makes it poor alloying elements for thin sections like plates,

sheets, flats etc. If Silicon is present > 10%, it can’t be rolled into a sheet.

If it is at 2-10%, rolled sheets with cracks, voids and residual stresses will be formed. If

Silicon is present < 2%, rolled sheets free of cracks and voids will be formed.

For this project, the presence of high level of Silicon is preferable because it helps in

accurate differentiation of the zones. At the same time, the presence of lower percentage of

Silicon is required for the specimen to be in sheet form. A compromise must be done while

choosing between these two factors. A material must be chosen in such a way that it has

sufficient amount of silicon to classify the zones and to roll the specimen into a sheet.

2.3. Tool Material – M2 Steel

M2 is a high-speed steel in tungsten–molybdenum series. The carbides in it are small and

evenly distributed. It has high wear resistance. After heat treatment, its hardness is the same

as T1 grade tool steel, but its bending strength can reach 4700 MPa, and its toughness and

thermoplasticity are higher than T1 by 50%. It is usually used to manufacture a variety of

tools, such as drill bits, taps and reamers. Its decarburization sensitivity is a little bit high.

3. FABRICATION AND HARDENING OF TOOL

3.1. Fabrication of M2 Tool Steel

The machining was done and the metal was removed from the rod by CNC lathe machine.

The machine was operated at a constant rotational speed throughout the process. The final

finishing to the job was given by cylindrical grinding.

Shaping of M2 tool steels can be carried out using grinding methods. However, they have

poor grinding capability and hence they are regarded as "medium" machinability tool steel

under annealed conditions. The machinability of these steels is only 50% of that of the easily

machinable W group or water hardening tool steels[10-14].

3.2. Heat Treatment of M2 Tool Steel

M2 tool steels were heat treated to achieve Rockwell harness value in range of 55 – 60. They

were pre-heated prior to hardening at 2610°C (4730°F) followed by rapid heating from

2610°C (4730°F) to 3960°C (7160°F). These steels were then cooled for 3 to 5 min and

quenched in air, salt bath or oil.

Annealing: M2 tool steels were annealed at 2925°C (5297°F) and cooled at 72°C (162°F) per

hour or even less.

Tempering: M2 steels were tempered at 1890°C (3434°F) to obtain Rockwell C hardness

from 60 to 65.

Hardening: Finally, M2 steels were hardened by heat treatment and quenching.

Figure 2 Fabricated and Hardened Tool

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S. Thirumavalavan, R. Sabarish, U. Ganesan

http://www.iaeme.com/IJMET/index.asp 1632 [email protected]

3.3. Steps to Harden M2 Tool Steel

Hardening of a tool steel is an important process of tool making. The hardening must be

performed carefully otherwise it leads to tool failure. A tool once hardened cannot be de-

hardened. The fabricated and hardened tools used in this work are shown in Figure 2 and 3.

The following are the steps that were followed while hardening the tool steel.

Hardening steel causes the structure of carbon to crystallize, similar to the way coal or

graphite changes to diamond under the heat and pressure within the earth. Without other

metals alloyed with it, steel to be hardened needs to have a carbon content of about 1.0

percent. This kind of steel is called high-carbon steel or tool steel.

Heat the entire piece of tool slowly at first. Then, concentrate the heat on the area that has

to be hardened, until that area glows red hot.

Shoulder Action: The table was then raised. The table along with the plates was pressed

against the tool. The rotating tool easily penetrates into the specimen because of AA6082 was

then in plastic state. Once the shoulder comes in contact with the plate surface, the table

movement rate was reduced. After the shoulder has plunged into the plate at 0.5mm depth, the

table movement was ceased.

Figure 3 During FSW

Transverse Movement: The table along with the plate was moved in transverse direction as

shown in Figure 8.5. The table gear was engaged with the lead screw by tripping the lever.

The table was moved at 30mm/min using a specific combination of gears[15-18]. Once the

weld was completed throughout the weld length, the table was lowered and the spindle was

switched OFF. The final welds obtained are shown in Figure 4

Figure 4 Welds Obtained using various Pin Profiles

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Experimental Investigation on Friction Stir Welded Aluminium–Scilicon Alloy

http://www.iaeme.com/IJMET/index.asp 1633 [email protected]

3.4. Post Weld Surface Cleaning

The burrs on the weld surface were removed by using chisels. The weld marks were then

removed by polishing it with rough emery sheet. The surface of the weld was then cleaned

with cleansing solution and it is wiped off with a dry cloth. The welds were ready for testing.

4. MICROSTRUCTURAL INVESTIGATION MOUNTING OF

SPECIMEN

The FSW specimens were cut in a band saw to reveal its cross section. The surface on which

the microstructures were to be seen is kept over a glass plate. A short hollow pipe, in this case

it is pvc was then placed encircling the specimen. Cold setting powder was then spread over

the specimen within the pvc. The powder must be filled in the pvc in such a way that the

specimen gets completely submerged into it. The cold setting solution was then added to the

powder. The cold setting solution solidifies the cold setting powder around the specimen. A

setting time of about 10 hours was provided for complete setting. After that the specimen was

ready for polishing. The mounted specimen is shown in Figure 5

Figure 5 Mounted Specimens

4.1. Rough and Fine Polishing

The mounted specimens were subjected to rough polishing in five grades of emery. Once the

surface was devoid of scratches, diamond polishing was done. Diamond polishing was done

by rubbing the specimens against a velvet wheel with alumina solution as a lubricant.

Alumina solution removes the Aluminium oxide layer formed on the surface.

5. MECHANICAL TESTING

Mechanical testing reveals the elastic and inelastic behaviour of material when force is

applied. A mechanical test shows whether a material or a part is suitable for its intended

mechanical applications by measuring elasticity, tensile strength, elongation, hardness,

fracture toughness, impact resistance, stress rupture and fatigue limit. The following two

mechanical tests were performed on the weld specimen.

Tensile Test

Micro-Vickers Hardness Test

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S. Thirumavalavan, R. Sabarish, U. Ganesan

http://www.iaeme.com/IJMET/index.asp 1634 [email protected]

5.1. Tensile Testing

Tensile testing, also known as tension testing is the fundamental materials science test in

which a sample is subjected to controlled tension until failure. The results from the test are

commonly used to predict how a material will react under other types of forces. Properties

that are directly measured via a tensile test are ultimate tensile strength, maximum elongation

and reduction in area

Uniaxial tensile testing is most commonly used for obtaining the mechanical

characteristics of isotropic materials. For anisotropic materials like composite materials and

textiles, biaxial tensile testing is required

The tensile test was performed on computerized tensile testing machine as shown in

Figure 6 at a loading rate of 5kN/min

Figure 6 Computerized Tensile Testing Machine

Table 1 Tensile Testing Machine Specification

Specification Value

Maximum Load 5 tonne

Gear rotation speed 1.25, 1.5 & 2.5 mm/min

Software FIE make india

5.2. Tensile Test Specimen Preparation

The weld specimen was cut using a vertical milling machine. The specimen was cut as per

ASTM E8 standard as shown in Figure 7. Cutting was made in such a way that the weld was

at the centre of the specimen as seen in Figure 8.

Figure 7 ASTM E8 Tensile specimen (Sattari 2012)

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Experimental Investigation on Friction Stir Welded Aluminium–Scilicon Alloy

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Figure 8 Weld Specimen Cut to E8 Standard

The tensile specimen was held between the fixed and moving beam by grippers. The

initial gauge length was noted. The machine was switched ON. The curve was generated by

the software. When the weld breaks, the machine was switched OFF and the specimen was

removed. The final gauge length and final area of cross section was measured and fed into the

software.

5.3. Tensile Test Results

The tensile testing of the various welds provide information about the ultimate tensile

strength, fracture point, % of elongation, maximum elongation, reduction in area etc. Other

properties like 0.2% proof stress was measured from the curve, joint efficiency can be

calculated using the following formula.

The stress vs strain curves obtained from the software for all the four different welds are

given in the following Figures 9, 10, 11 and 12.

Figure 9 Stress vs Strain curve for Taper Cylindrical Threaded Pin Weld

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S. Thirumavalavan, R. Sabarish, U. Ganesan

http://www.iaeme.com/IJMET/index.asp 1636 [email protected]

Figure 10 Stress vs Strain curve for Plain Cylindrical Threaded Pin Weld

Figure 11 Stress vs Strain curve for Taper Cylindrical Pin Weld

Figure 12 Stress vs Strain curve for Plain Cylindrical Pin Weld

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Experimental Investigation on Friction Stir Welded Aluminium–Scilicon Alloy

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Table 2 Comparison of Tensile Test Results

Properties

Ultimate

Tensile

Strength

(kN/mm2)

0.2% Proof

Stress (kN/mm2) % of Elongation

Reduction in

Area (%)

Joint Efficiency

(%)

Taper cylinder

threaded 0.182 0.138 14.867 35.964 58.71

Plain cylinder

threaded 0.183 0.132 3.5 9.222 59.03

Taper threaded 0.167 0.127 6.667 32.645 53.87

Plain threaded 0.134 0.083 1.033 6.761 43.23

From Table 10.2, it is seen clearly that threaded pins have dominant tensile properties than

the unthreaded pins. Between the two threaded pin profiles, the taper cylindrical threaded pin

profile has higher elongation characteristics than the plain cylindrical threaded pin profile. In

case of UTS and joint efficiency, the variation between the two threaded profiles was not

much high. So, it could be concluded that the weld made of taper cylindrical threaded pin

profile has dominant tensile characteristics among the four pin profiles.

5.4. Micro-Vicker’s Hardness Testing

Micro-Vickers hardness test is used to determine the hardness of the material to deformation.

When testing metals, indentation hardness correlates linearly with tensile strength. Figure 13

is the Micro Vickers hardness tester used.

Figure 13 Micro Vickers Hardness Tester

Table 3 Micro Hardness Testing Machine Specification

Specification Value

Load Range 10 gm to 1 kg

Magnification 100x and 1500x

Make & Model Baieiss – V test

In Micro-Vickers hardness test, a diamond indenter of specific geometry was impressed

into the surface of the test specimen using 3 kN loads. It has forces of 2N and produce

indentations of about 50 m. The specifications of Vickers tester is given in table 14. It has

been found that microhardness of almost any material was higher than its macrohardness.

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S. Thirumavalavan, R. Sabarish, U. Ganesan

http://www.iaeme.com/IJMET/index.asp 1638 [email protected]

Micro-Vickers hardness test dis not require any special specimen preparation. The

specimen that was used for micro examination was used for finding hardness. The specimen

was placed on the table. The microscope was adjusted to get a clear image of the surface. The

table was moved towards the indenter. Now the indenter controller was switched ON. The

load of 300 gms was applied using the diamond tip indenter for a time of 10 secs. The

indenter automatically made an impression and returns back to its home position. The table

was moved towards the microscope. The focusing on the surface was done if required. In the

software, all the four corners of the indentation were marked. The software automatically

calculated the hardness value.

Figure 14 Micro-Hardness Curve for AA 6082 Welds

Table 4 Average Hardness at the Weld Nugget

Pin Profile Hardness Number (VHN) Distribution

Taper Cylindrical

Thread 68.71

Non-Uniform (max. at the RS and

decreases towards the AS)

Plain Cylindrical

Thread 75.03

Almost uniform (high at the interface and

low at weld centre)

Taper Cylinder 68.43

Non-Uniform (max. at the RS and

decreases towards the AS)

Plain Cylinder 50.87 Uniform (lowest at the weld centre)

It can be seen from the hardness curve in Figure 14 and Table 4, plain cylindrical threaded

pin weld has highest hardness of them all. So, it could concluded that plain cylindrical

threaded pin profile has high microhardness characteristics[19-20].

6. RESULTS & DISCUSSIONS

The microstructural analysis and mechanical testing on the friction stir welded joints were

performed and their results were obtained. By carefully interpreting these results, the

microstructural and mechanical characteristics of the four different welds could be briefly

described.

In case of the material flow around the pin, the threaded pins have given better material

mixing than the unthreaded pin profiles. This is because of the fact that the threads in the pin

transported the material from bottom to the top. In Taper cylindrical threaded pin profile, the

material near the threads gets caught by the rotating threads and moved the material upwards.

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Experimental Investigation on Friction Stir Welded Aluminium–Scilicon Alloy

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On moving up, the material undergoes a pressure rise because of the tapered profile. The

tapered pin occupies most area at the top region than at the bottom. The material then comes

out to the surface because of pressure. That material was again pushed back into the weld

zone by the shoulder. The material then moves downwards due to the shoulder effect. The

material flow in Plain cylindrical threaded pin profile was almost same to that of taper

cylindrical threaded pin with only exception that the pressure throughout the flow was

uniform and high.

In taper cylindrical pin profile, the material movement in vertical direction was restricted

because the surface was devoid of threads. The rotating pin imparted centrifugal force to the

material that comes in immediate contact with it. The material moved only around the tool in

its horizontal plane with no movement in vertical. In plain cylindrical pin profile, the pressure

was high throughout the thickness direction and flow was similar to taper cylindrical pin

profile.

Table 5 Grain Size Comparison

Pin Profile Taper cylindrical

thread

plain cylindrical

thread

Taper thread plain thread

Grain size (mm) 3 – 4 4 – 5 4 – 5 6 – 7

Table 5 indicates the grain size obtained in the weld nugget of the four different welds

made. From the table, it is clear that the taper cylindrical threaded pin results in finer

refinement of the grains. The taper cylindrical threaded pin refined the grains of 25 – 30 m

size in the base material to 3 – 4 m size at the weld nugget. The fine refinement of grains in

the weld nugget indicates that taper cylindrical threaded pin has given better weld than the

rest of the profiles.

Table 6 Percentage of Elongation Comparison

Pin Profile Taper cylindrical

thread

plain cylindrical

thread

Taper thread plain thread

% of Elongation 14.867 3.5 6.667 1.033

Table 6 indicates the % of elongation obtained through tensile testing of the four different

welds. From the table, it is clear that the weld made of taper cylindrical threaded pin profile

has high ductility and fails after an elongation of 14.867%. Only taper cylindrical threaded pin

has given such elongation. The remaining welds had not given atleast half the elongation. So,

the tensile properties of the weld made of taper cylindrical threaded pin were better than the

rest of welds

Table 7 indicates the micro-hardness obtained through Micro-Vickers hardness testing

Pin Profile Taper cylindrical

thread

plain cylindrical

thread

Taper thread plain thread

Hardness No (VHN) 68.71 75.03 68.43 50.87

Table 7 indicates the micro-hardness obtained through Micro-Vickers hardness testing of

the welds. The micro-hardness value of the weld made of plain cylindrical threaded pin

profile was the highest among the welds made. The plain cylindrical threaded pin has

hardness value of 75.03 VHN. But its % of elongation was only 3.5%. So, it could be said that

the weld made of plain cylindrical threaded pin was more brittle and couldn’t be said as better

weld. On moving to the next highest hardness value, weld made of taper cylindrical threaded

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S. Thirumavalavan, R. Sabarish, U. Ganesan

http://www.iaeme.com/IJMET/index.asp 1640 [email protected]

pin has hardness value of 68.71 VHN and 14.867% of elongation. This clearly indicates that it

has undergone a ductile fracture. So, the weld made of taper cylindrical threaded pin profile

exhibit high mechanical properties than the rest of welds.

It could be summarized that the weld made of taper cylindrical threaded pin has high

mechanical properties and finer grain refinement in weld nugget. The weld made of taper

cylindrical threaded pin is the optimal weld among the four welds made.

7. CONCLUSIONS

In the present research work, effects of tool pin profile on microstructure and mechanical

properties of Friction stir welded Al - Si joints were investigated using four different tool pin

profiles, i.e., taper cylindrical threaded, plain cylindrical threaded, taper cylindrical and plain

cylindrical pin profiles. Based on the results obtained in this work, the following conclusions

could be drawn:

Sample welded using taper cylindrical threaded pin profile showed fine recrystallized grains

of about 3 m. The grains were evenly distributed throughout the weld nugget region.

The mechanical properties of the joints were in relationship with the grain size and therefore,

sample welded using taper cylindrical threaded pin profile showed higher mechanical

properties relative to sample welded using other pin profiles. It has the elongation of 14.867%

which was highest among the welds made.

The axisymmetric flow of material around the tool pin and also along the vertical direction

was a prime reason for such grain refinement and increased mechanical properties in weld

made of taper cylindrical threaded tool pin profile.

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Experimental Investigation on Friction Stir Welded Aluminium–Scilicon Alloy

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