Effect of the Metal Transport on the Mechanical Properties of Al-2Si Alloys Processed through Friction Stir Welding Proc
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INTRODUCTION
NOWADAYS, aluminum alloys are extensively used in various applications like defense, aerospace, automobiles, and many more. With the demand of the usage of aluminum in the manufacturing processes, it is necessary to study the process parameters, depending upon the applications for its quality improvement. Joining of the metals for a particular application needs a wider focus in understanding the mechanical properties which determine its quality during the process. Friction stir welding is one of the joining processes, and nowadays, this process is used extensively in the various military application and manufacturing sectors. The friction stir welding process is a joining of two metals by plunging the tool, which is rotating and moving between the metals. The rotational speed and feed rate of the tool determine the quality of the weld. Lots of works have been carried out to understand the quality of the weld joint with various process parameters of the tool. The careful selection of the processes parameters in FSW helps avoid porosity, hot cracking, and distortion in the weld joint. Jayaraman[1] studied the effect of the process parameters in FSW relating to the base metal. He found an empirical equation which can determine the optimum process parameters to fabricate defect-free joints by knowing the base metal properties. The stiffness of the weld joint mainly depends on the plunging force, rotational speed, and feed rate of the tool.[2] Based on the process parameters, the mechanical properties, like tensile strength and hardness, are studied by various authors.[3–6] There are some works on the effect of tool selection on the weld quality. Fujii[5] A. SHAILESH RAO and YUVARAJA NAIK are with the Department of Mechanical Engineering, KS School of Engineering and Management, Bangalore, 671-2280, India. Contact e-mail: [email protected] Manuscript submitted January 4, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS B
studied the effect of tool shape on the mechanical properties, and microstructures are explained. There are also studies on heat transfer during the process. Ma[7] noticed the change in the microstructure and its properties with the different tool geometry. Song[8] used the finite difference method to determine the heat distribution for Al6061-T6 alloy. The experiments were carried out for the alloy and its mechanical properties are then correlated with the results formed in the software. Nandan[9] studied the heat and material flow during the friction stir welding process. From the above, lots of investigations have studied the effects of the process parameters, tool geometry modification, and heat distribution on weld joint quality. The material flow during the process also determines the quality of the weld joint and a small amount of research work has been carried out in this direction. Material flow using a tracer in the process has been studied by various researchers. Copper foil,[10] small steel shots,[11] and many more are used as tracers to track the material flow in the FSW processes. Mishra
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