Certain Investigations on the Effect of Welding Parameters of Two Aluminium Alloys AA6101-t6 and AA1350 Using Friction Stir Welding

Aluminium alloys are extensively used in the aerospace, transportation, and electrical industries due to its light weight, non-corrosive, and conductive properties. As a result, welding aluminium alloys is unavoidable. The use of traditional welding procedures to join aluminium alloys leads in cracks during solidification, significant residual stresses, and inadequate dimensional stability, all of which lead to poor weld quality. Friction Stir Welding (FSW) is a unique and environmentally friendly solid state welding technology that was first developed for the welding of aluminium alloys. In FSW, a non- consumable rotating tool generates frictional heat, which causes plastic deformation and mixing of the material. The temperature that base metals are subjected to is lower than the melting temperature. The granules in the weld zone are refined by thermomechanical deformation. As a result, the faults relating to fusion welding procedures can be avoided, improving the weld's mechanical and metallurgical characteristics. Friction stir welding (FSW) is the most inventive and efficient method of producing Aluminium Matrix Composites by changing the composition at specific points. Grooves are carved into the base metal and filled with ceramic particles in this process. The tool pin combines the particles to the plasticized base metal while stirring. The aluminum alloys AA6101-T6 and AA1350 are widely used in the electrical industry, but no attempt to unite them has been done previously. Two phases of examination were conducted in this study. The high-strength AA6101-T6 aluminum alloy was employed on the advancing side, while the low-strength AA1350 aluminium alloy was employed on the retreating side, and a hexagonal pin profiled High Carbon High Chromium steel tool was used throughout the three phases. Tensile tests, bending tests, wear tests, and hardness measurements were used to assess the weld quality. During the first part of the study, various combinations of tool traversal speed, rotational speed, and tilt angle were used to fabricate the square butt joints. Single pass welding was used to create the joints. The effects of various welding settings on weldment qualities were thoroughly investigated. Finer grains and improved mechanical qualities were achieved by combining a rotational speeds of 1075 rpm, a traversal speed of 77 mm/min, and a tilt angle of 2°. Rotational speed is the most influential factor for tensile strength, hardness, and weight loss, according to ANOVA and S/N ratio, and tool tilt angle has a significant impact on the joint's bending strength. Various levels of tool offset distance were used in the second part of the study. Single and double pass welding procedures were used for each tool position. For all fabrications, a constant rotational speed of 1075 rpm, traversal speed of 77 mm/min, and tilt angle of 2° were established. With a 2 mm tool pin offset on the advancing side and double pass welding, the weld was strong and defect free. Hence, there was an increase in tensile strength, bending strength, and wear resistance. The most affecting characteristic for all joint characteristics is tool pin offset distance, according to ANOVA and S/N ratio.