Analysis and characterization of weld quality during butt welding through friction stir welding

摘要

In the present study, butt weld produced by friction stir welding of aluminium 1060 alloy has been analyzed. Destructive test, non-destructive test, and SEM image analysis methods have been implemented to investigate the microstructural evolution and mechanical properties of welded joints. The effects of tool rotation speed, welding speed, tool pin profile and tool offset have been investigated to optimize welding conditions for required weld properties. Face-centered central composite design of response surface methodology has been adapted to analyze the effect of parameters with an optimal number of experiments. It has been observed that weld produced with threaded pin tool has higher ultimate tensile stress and ultimate flexural stress. Radiography test has shown that cracks are not present in the produced weldment. From the study of the fracture surface of the tensile test specimen, it has been found that ductility of weld is highest at the top area and decreases towards the bottom area of weld. Dimple formation has been found at the top area of the fracture surface but has been absent in the bottom area of weld. Vickers hardness of weld zone and the heat affected zone has found to be less than the base material.