In this research work, the effect of SiC and Al 2 O 3 reinforcements is analyzed on the interlock dissimilar joints. The joints are welded with different wt% of SiC and Al 2 O 3 (1 to 5 wt%) placed in the groove of 0.5 mm depth between the sheets. The rotational speed of 1400 rpm, weld speed of 30 mm/s and plunge speed rate of 0.06 mm/s are selected input parameters to perform the weld. Thereafter Micro-hardness, tensile strength and microstructure properties of interlock lap joints were investigated. AA7075 T6-AA7475 T7/2wt% SiC showed maximum tensile strength and hardness of 190.51 MPa, 220 HV respectively. All the SiC reinforced FSW interlock lap joints mechanical properties showed improvement on the static properties than the joints made with Al 2 O 3 reinforcement, because of the hard silica particles and substantial increase in grain refinement that occurred in the stir zone of the reinforced welded joints. The microstructure analysis of joints revealed that reinforcements have mixed uniformly and homogenous distribution occurred in the entire weld. The fracture analysis revealed that the joints with SiC possess ductile fracture.
Friction stir welding (FSW) technique was preliminary developed to join various low strength and high strength alloys by considering different inputs and known to surpass the flaws which occur in conventional welding processes. The present study is focused on the FSWed interlock lap joint of AA7475-T7 using three-level three factor (33) full factorial design methodology to study the correlation among process parameters with the lap shear strength and hardness. To compare the strength and hardness of interlock lap joint, a typical lap joint has been made with an optimized input parameter obtained from the FSW interlock lap joint. Microstructure analysis, hardness and tensile strength of FSWed interlock lap joints and typical lap joints were done to analyze the robustness of the welds made. Results proved that the strength of FSWed interlock lap joints is high compared to typical lap weld with a ultimate tensile strength of 172.88 N and hardness of 200 HV when the process parameter level is at tool rotation speed of 1400 r/min, welding speed 30 mm/s plunge speed rate 0.06 mm/s. At the tool rotation speed of 1400 r/min dynamic recrystallization of the material occurs which thereby leads to the formation of fine grains in the SZ of the weld metal.
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