This research aimed to study the induction in-situ heated hybrid friction stir welding (IAFSW) method to join AA5052 aluminium alloy with X12Cr13 stainless steel (SS) to enhance joint strength. The potency of this method on the mechanical properties and microstructural characterizations were also investigated. The results show that the transverse tensile strength gained was 94% of the AA5052 base metal that is 229.5 MPa. This superior strength was achieved due to the annealing that happened to the AA 5052 region and elevated plastic flow in the weld zone by the in-situ induction heating, which resulted in the elongation of the weld region. The microstructure characterization indicates that a refined grain structure was gained in the nugget zone without defects.
This work presents the formulation of a mathematical model with process parameters and tool geometry to predict the response, joint strength, of double side friction stir welded aluminium alloy 6082-T6. The welding was carried out on 8 mm aluminium alloy plates. The process parameters considered were tool rotational speed or spindle speed, welding speed and shoulder penetration, and the tool geometries considered were pin profile and shoulder profile. A five-factor, five-level central composite design was used to determine the number of experiments. The tensile strength of the welded specimens was tested, and its correlation with process parameters was assessed. A mathematical model had been developed to predict the tensile strength using response surface methodology at 95% confidence level, and it was validated using analysis of variance.
Friction Stir Welding (FSW) was carried out to examine the influence of filler materials and varying process parameters on the microhardness and the joints corrosion resistance properties. Aluminium alloys 6082 and 5052, having 8 mm thickness was joined by varying parameters. The primary process parameters are rotational speed, tool travel speed, plunge depth, filler holes centre distance and filler ratio. The hardness at the weld nugget zone and corrosion rate evaluations were analyzed. The best results were obtained for the parameter combinations of 1150 rpm tool rotation, 130 mm min−1 tool travel, 0.2 mm tool plunge, the filler holes centre distance 2 mm and a powder filler made of 95% magnesium and 5% chromium.
Induction Heated Friction Stir Welding (IH-FSW) was conducted using two varying parameters and two fixed parameters. The microstructure evaluation shows that the nugget zone’s grain size is smaller while comparing with the parent metal. Due to dynamic recrystallization during the induction heated friction stir welding, well-equiaxed grains were found in the nugget zone. The microhardness test reveals that the welded region have improved hardness than the parent metal; the high hardness was attained in the heat-affected zone. The 3 h and 24 h of weight-loss corrosion test methods were conducted using the coefficient of 0.5 M H2SO4, showing that the stir zone’s corrosion resistance is better than the parent material. The given parameter combinations obtain the best results, tool rotation of 1250 rpm, welding speed of 45 mm min−1, shoulder penetration of 0.50 mm and induction heat input of 441.8 °C at 50 W.
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