International Journal of Science, Engineering and TechnologyAuthors: Raj Kumar Pathak, Tanvir Singh
Abstract: This research work deals with studying the effect of welding parameters on the mechanical and metallurgical properties of friction stir-welded joints of AA1100 aluminum alloy. FSW process parameters with tool rotational speed range from 1400 to 1800 rpm and traverse speeds from 80 to 120 mm/min were employed. Results revealed that higher ultimate tensile stress (127 MPa–148 MPa) and percentage elongation (1.9- 11%) with joint efficiency (82-95%) for every set of rotational speed and traverse speed compared to the base material (155 MPa, 75MPa and 12% of ultimate tensile strength, yield strength and % elongation, respectively). The joint efficiency of most of the samples is around 70–80 % with the highest joint efficiency of 95.64% of FSW welds produced at 1800 rpm and 100 mm/min of tool rotational speed and traverse speed due to the fine grains, due to the dynamic recrystallisation, and an onion-ring structure, which improves the properties. Surface appearance and macrostructure results reveal that the weld produced at a higher tool rotational speed of 1800 rpm and moderate traverse speed of 100 mm/min leads to good surface appearance with a flawless weld. Furthermore, the welds produced at 1800 rpm/80mm/min and 1600rpm/120 mm/min of tool rotational and traverse combination show the highest values of microhardness in the probe region due to the exertion of higher stresses because of the round dome shape that deforms the grains to a higher extent, which increases the microhardness values.
