Design and Development of FSW Process Parameters for dissimilar alloys

Abstract

Friction stir welding (FSW) is a solid-state joining process widely used for joining similar and dissimilar materials and achieving high-quality welds. In this project, the aim was to investigate the effects of process parameters on the weld quality and mechanical properties of FSW joint for two different grades Aluminum. The objective of this project was to investigate the feasibility of friction stir welding (FSW) on a milling machine and evaluate the quality of the welded joint through simulation and testing. The FSW process was simulated using finite element analysis (FEA) to predict the temperature distribution, residual stresses, and deformation during the welding process. The mechanical properties, including tensile strength and hardness, were evaluated through standard testing methods. The results demonstrated the successful fabrication of aluminum-to-steel joints using the FSW process. The welds exhibited a fine-grained microstructure and high joint strength, indicating the feasibility of using FSW for such dissimilar material combinations. This study provides valuable insights into the FSW process for two different grades Aluminum joints and contributes to the development of reliable welding techniques for similar applications.