Impact of Tool Pin Profiles and Nanopowder Addition to Nugget Zone on FSW of Aluminum Alloys
J. Environ. Nanotechnol., Volume 13, No 4 (2024) pp. 114-121
Abstract
Friction stir welding (FSW) process is a type of solid-state welding process. FSW is preferred due to no chemical reaction, melting, secondary phase formation and microstructure-controlled process. The absence of smoke and spark can be categorized as an eco-friendly welding process. In this work, the FSW process is carried out on AA 2024 and AA 7075 aluminum alloys with Al2O3 filled in the nugget zone. The micro hole is performed before welding on the nugget zone to fill nanoparticle addition. Process parameters considered are tool pin profile, tool rotational speed, and welding speed. Three different types of tool pin profiles are considered namely square, hexagon and circular in cross-section. Taguchi L9 experimental steps are followed to perform the experiments. Performance parameters considered are tensile strength, bending strength and micro hardness of the welded sample. The performance of FSW samples is influenced by material mixing, which is significantly influenced with tool pin profile. Tool pin profile is directly influenced by contact area, material mixing, fine refined structure and appropriate heat. The result of experimentation is understood as better pulsating action, stir action and material mixing with hexagon pin profile and nano Al2O3 filled in the nugget zone. Characterization study is carried out on wedded area on FSW sample to evaluate microstructure changes to realize the weld quality. It is noticed that fine refinement structure after FSW and provides good mechanical properties.
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