Optimization of Friction Stir Welding Parameters of Al A9 1050-O With Respect To Weld Tensile Strength and Soundness

Abstract

Friction stir process is a welding process whose advantages result from the fact that the process occurs in solid-state. This enables welding materials that are difficult to weld with fusion welding processes. Applications of FSW includes many fields of industry such as shipbuilding and marine, aerospace, land transportation, construction, electrical industry, and welding of pipes and hollow sections. FSW welding process variables have a direct impact on the behavior of the welding process in terms of weld joint quality and process characteristics. The phenomenon underlying the mechanism of the welding process determines needs to be further investigated through theoretical and experimental analysis. It is therefore important to obtain an optimum combination of the welding parameters that lead to the best welding quality. To achieve these goals, an experimental set up on a standard milling machine was prepared using a specially designed welding fixture that is provided with the necessary measuring devices for monitoring and controlling the important process parameters. A series of planned experiments was conducted to test the effect of tool speed (rpm), welding speed (mm/min), and welding tool inclination angle on weld properties. Their effects on the weld quality characteristics in terms of tensile strength, hardness, and weld soundness are analyzed.  Optimum conditions for welding Aluminum A9 1050-O have been determined with respect to maximum tensile strength of the welded joint, and weld soundness.