Title: Effect of the process parameters on the mechanical properties of the weld joint in the friction stir welding process

Authors: Sanjay Kumar Jha; Ravi Shankar Anand; Prashant Prakash

Addresses: Production Engineering Department, Birla Institute of Technology, Mesra, Ranchi, 835215, India ' Mechanical Engineering Department, Birla Institute of Technology, Mesra, Patna Campus, Patna, 800014, India ' Production Engineering Department, Birla Institute of Technology, Mesra, Patna Campus, Patna, 800014, India

Abstract: This article predicts the effect of the input process parameters on the mechanical properties of the weld joint of the aluminium alloy in the friction stir welding process using statistical techniques that are ANOVA, regression and surface response methodology. Mechanical properties of the weld joint almost constant with welding speed at particular tool rotation speed and tool pin geometry. The effect of the tool rotation speed is nonlinear on the mechanical properties. At the moderate tool rotation speed (900 rpm to 1,120 rpm), tensile and percentage elongation are maximum, whereas grains size and hardness are minimum with all tool pin profiles and welding speed. Steeped tool pin profile produces maximum tensile and percentage elongation whereas minimum hardness and grain size value among the all tool pin profile produced surface responses. Stepped tool pin profile produces superior mechanical properties of the weld joint with respect to other tool pin profiles.

Keywords: tool pin profile; welding speed; tool rotation speed; response surface method; mechanical properties; friction stir welding; FSW; ANOVA; regression analysis; hardness; grain size.

DOI: 10.1504/IJMATEI.2022.124195

International Journal of Materials Engineering Innovation, 2022 Vol.13 No.2, pp.110 - 127

Received: 11 Feb 2021
Accepted: 03 Jul 2021
Published online: 18 Jul 2022 *

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