Friction Stir Welding is a solid state welding processused in aerospace, automobile and machine tool industry. However, corrosion of the friction stir weld zones is still a major drawback that needs to be addressed immediately; hence the current work focuses on the corrosion characterization of the friction stir weld joints of dissimilar aluminium alloy. In the present research, friction stir welding is carried out at different set of parametric conditions and the weld joints are characterized for weight loss corrosion in sodium chloride saline medium. The friction stir weld joints of dissimilar aluminium alloys are obtained using three sets of process parameters viz., tool profiles of straight cylinder, taper cylinder, and straight triangular; tool rotational speed of 800 rpm, 1000 rpm, and 1200 rpm; tool feed rate of 100 mm/min, 120 mm/min, and 140 mm/min; tool offset of 0.5 mm, 0 mm, and-0.5 mm. The corrosion characterization is carried out for friction stir weld joint using immersion tests. The results give an overview of the variation in the corrosion with time, and the effect of process parameters on the corrosion behavior of weld joints.
Welding process in vehicle structures has gained importance, especially for better strength and mechanical properties. Hence, there is vast research going on in the domain of newer welding techniques. Friction Stir Welding (FSW) is one of them. FSW is used in this research to join two different grades of aluminium alloys by varying the process parameters. The process parameters are optimized based on the Design of Experiments (DoE) and the Taguchi techniques. From the experimental findings for different process parameters, the optimized set of conditions involving the normal, transverse forces and the torque are determined. Further, the process methodology is validated.
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