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Effect of two distinctive tool designs along with other tool related parameters including speed of traverse of tool and offset distance of tool pin during friction stir welding of dissimilar AZ91C and AZ31B alloys of Mg were investigated. Experimental recordings revealed that all the joints fabricated during 1 st set of investigations employing cylindrically tapered pin geometry and their offset distances being 0.5 mm or 1mm towards any one of the parent metals possessed flaws. Joint No: II-3 fabricated in 2 nd set of investigations by employing 15mm diameter inner shoulder tool with threaded cylindrical tapered pin geometry at a tool offset distance of 0 mm was found be free from flaws. This joint exhibited a tensile strength of 186 MPa which was 78.81% of AZ91C and 70.72% of another parent metal AZ31B. Existence of intermetallic phased constituents, namely, Mg 17 Al 12 in several regions of fractured surfaces have contributed to the supplementary brittleness in the zone of nugget, and have reduced the tensile strength of the joint.

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The intent of automotive sector for 21st century is to save fuel and reduce emissions. Due to this, the automotive designers are revisiting automotive systems and its parts for reducing the mass of the vehicles. For a suspension system, leaf spring is one of the key targets for weight reduction because it adds to unsprung mass which affects the ride quality of the vehicle. In this present study, a novel material such as a glass fiber reinforced plastic (GFRP) was selected. The polyester resin was used for conducting the numerical analysis via finite element analysis technique using ANSYS R15.0 software. Stresses, deformation and strain energy results for both steel and composite leaf spring material were obtained. Result shows that, the composite spring has a maximum strain energy than the steel leaf spring. The design constraints were stresses, deformations and strain energy. Compared to the steel spring, the composite spring (S-glass fiber) resulted in higher deformation, strain energy and stress.