Effect of tool pin profile on the tensile characteristics of friction stir welded joints of AA8011

OBRABOTKAMETALLOV Vol. 25 No. 4 2023 114 EQUIPMENT. INSTRUMENTS Eff ect of tool pin profi le on the tensile characteristics of friction stir welded joints of AA8011 Yogendra Rajpoot 1, a, *, Avadesh Sharma 1, b, Vibhooti Mishra 2, c, Kushal Saxena 1, d, Desh Deepak 1, e, Shyam Sharma 3, f 1 Department of Mechanical Engineering, Rajkiya Engineering College Mainpuri, Uttar Pradesh, India 205119 2 Department of Mechanical Engineering, Rajkiya Engineering College Azamgarh, Uttar Pradesh, India 276201 3 Department of Mechanical Engineering, Manipal University Jaipur, Rajasthan, India, 303007 a https://orcid.org/0000-0002-9662-0903, yogendrasingh.rajpoot@recmainpuri.in; b https://orcid.org/0000-0002-2795-6497, aksharma@recmainpuri.in; c https://orcid.org/0000-0002-5039-3573, vibhooti1810@gmail.com; d https://orcid.org/0000-0001-6982-3636, saxenakushal05@gmail.com; e https://orcid.org/0000-0003-2662-9571, dd08iitd@gmail.com; f https://orcid.org/0000-0002-1510-5871, shyamsunder.sharma@jaipur.manipal.edu Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2023 vol. 25 no. 4 pp. 105–116 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.4-105-116 ART I CLE I NFO Article history: Received: 06 July 2023 Revised: 01 August 2023 Accepted: 15 August 2023 Available online: 15 December 2023 Keywords: FSW Tool pin Profi le Tensile Strength Acknowledgements Express our gratitude to our undergraduate and graduate students Mohd Lareb, Mr. Chandrashekhar and Mr. AnkitArya for assistance in conducting the experiments. ABSTRACT Introduction. Aluminum alloys are in abundant demand of shipbuilding and aircraft industries. This study emphasizes on the eff ects of two diff erent tool pin profi les on the tensile characteristics of welded joints made of AA8011 aluminum alloy welded joints. The joining technique used is friction stir welding (FSW) due to its unique characteristics such as very low heat aff ected zone when joining in a solid state. The microstructure and mechanical properties of the welded joint are infl uenced by the geometry of the tool and such parameters as rotational speed and traverse speed of the tool. The methods of investigation. The experiments on FSW were performed on universal milling machine with taper cylindrical and cylindrical threaded tool pin profi les using the three diff erent combination of tool rotational and traverse speed (a) 320 rpm, 45 mm/min; b) 400 rpm, 50 mm/min; c) 575 rpm, 60 mm/min.). To analyze the joint characteristics, tensile tests were conducted and ultimate tensile strength as well as joint effi ciency was calculated for individual joint. Results and Discussion. Based on the revised results, it is evident that higher RPM values have a positive impact on joint effi ciency and tensile strength for both the taper cylindrical pin profi le and the threaded cylindrical pin profi le. The fi ndings show that the joint effi ciency and tensile strength are consistently higher for the threaded cylindrical pin profi le compared to the taper cylindrical pin profi le, regardless of the RPM and feed rate. From the results, it was found that joint effi ciency and tensile strength is maximum at higher RPM irrespective of the tool pin profi le i.e. 73.6 % and 123 MPa for taper cylindrical pin profi le and 85 % and 142 MPa for threaded cylindrical pin profi le at 575 rpm, 60 mm/min. These are the highest in comparison to 72.5 % and 119 MPa at 320 rpm, 45 mm/min and 70.1 % and 115 MPa at 400 rpm, 50 mm/min for taper pin profi le tool and 82.6 % and 138 MPa at 320 rpm, 45 mm/min and 77.8 % and 130 MPa at 400 rpm, 50 mm/min for threaded cylindrical pin profi le. Overall, the study demonstrates that joints obtained using the threaded cylindrical pin profi le demonstrate higher joint effi ciency and tensile strength than those prepared using the taper cylindrical pin profi le. The highest joint effi ciency and tensile strength of 84.5 % and 142 MPa, respectively, were achieved using the threaded cylindrical pin profi le at 575 rpm and 60 mm/min. For citation: Rajpoot Y.S., SharmaA.K., Mishra V.N., Saxena K., Deepak D., Sharma S.S. Eff ect of tool pin profi le on the tensile characteristics of friction stir welded joints of AA8011. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 4, pp. 105–116. DOI: 10.17212/1994-6309-2023-25.4-105-116. (In Russian). ______ * Corresponding author Rajpoot Yogendra Singh, M.Tech (Engineering), Assistant Professor Department of Mechanical Engineering, Rajkiya Engineering College Mainpuri, 205119, Uttar Pradesh, India. Tel.: +917014210761, e-mail: yogendrasingh.rajpoot@recmainpuri.in References 1. Thomas W.M., Nicholas E.D., Needham J.C., Murch M.G., Temple-Smith P., Dawes C.J. Friction Stir Butt Welding. Patent GB, no. 9125978.8, 1991. 2. Dawes C., Thomas W. Friction stir joining of aluminum alloys. TWI Bulletin, 1995, vol. 6, pp. 124–127. 3. Rhodes C.G., Mahoney M.W., Bingel W.H., Spurling R.A., Bampton C.C. Eff ects of friction stir welding on microstructure of 7075 aluminium. Scripta Materialia, 1997, vol. 36 (1), pp. 69–75.

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