Non-Destructive Evaluation of Friction Stir Welded Thin Zn-Coated Metal Sheets with Lap-Joint Configuration

Abstract:

Friction stir welding (FSW) can be classified as a new non-fusion welding technique if compared to other conventional welding techniques. In this study, a thin Zn-coated metal sheet was welded using the FSW technique with a lap-joint configuration. The weld joint was inspected using non-destructive testing (NDT) methods to determine the quality of the weld produced. There are two main parameters used in the experiment, which are rotational speed [RPM] and traverse [mm/min]. The design of the welding experiment is carried out using the surface response technique with the circumscribe central composite design method. This experiment was conducted using two factors and two levels of design of the experiment setup. All the samples are successfully welded and examined by visual inspection and radiographic testing (RT) to identify defects in the weld. Welding defects are plotted into the graph to assist in the process of analyzing the trend of defects. Several defects have been discovered such as flash formation, thinning material, through-hole, and high-density solid inclusion during the experiment. As a result of the study, it is possible to make a preliminary overview of the appropriate parameters used for FSW of thin Zn-coated metal sheets. In addition, welding defect information from the NDT inspection can assist in the process of preparing specimens for destructive tests.

• Periodical: Engineering Headway (Volume 15)
• Pages: 115-123
• DOI: https://doi.org/10.4028/p-sFC0u0
• Online since: January 2025
• Authors: Shaik Syahman*, Safian Sharif, Mohd Ahmad Zaharuddin Faridh, Mokhtar Awang
• Keywords: Friction Stir Welding, Non-Destructive Test, Radiographic Testing, Visual Inspection, Weld Defect

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