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a b s t r a c tThe surface texture of friction stir weld is related to internal structure of weld. The statistical image parameters along good and defect weld regions are quantitatively evaluated for quality from the weld bead images, which are processed and analyzed using machine vision technique and X-ray radiography. The weld strength obtained along the weld regions showing similar variations in Acoustic Emission (AE) data, which was acquired during welding and image data of the weld bead are analyzed to assess the weld quality. The combined model developed using limiting values of image data and AE data along different regions of weld evaluate the weld quality more reliably.

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Abstract:Friction Stir Welding is a recent emerging welding technology invented by The Welding Institute (TWI) in 1991. This has evolved into a process focused on joining of arcweldable (5xxx and 6xxx) and difficult to weld (2xxx and xxx) aluminum alloys. The present study is aimed to determine the optimum process parameters and identify the most influencing significant parameter along with percentage contribution of each parameter on tensile strength of Friction Stir Welded AA 7075-T6 aluminum joints by conducting specific number of experiments using Taguchi approach. In this study, tool pin profiles having conical and cylindrical head with grooves are used. It has been observed that the tool rotational speed exhibits more influence on tensile strength in both the tools. Further the tool having conical profile results in better joint efficiency than the tool having cylindrical profile. The method described in this paper for the prediction of tensile strength and optimization of process parameters can eliminate the need for performing more experiments on the basis of conventional trial and error method.

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