Impact of Tool Pin Geometry and Optimized Process Parameters on Mechanical Properties of Friction Stir Welded AZ80A Mg Alloy

Abstract:

In this paper, the influence of optimized FSW process parameters namely tool rotational speed, feed rate, mechanical axial force and impact of tool pin geometry on the mechanical properties of AZ80A Mg alloy are experimentally investigated in a detailed manner. M35 grade High Speed Steel (HSS) tool with three different pin geometries namely straight cylindrical, threaded cylindrical and taper cylindrical was employed in this investigation. The joints obtained under these conditions are subjected to tensile tests as per ASTM (American Society for Testing and Materials) B557M – 10 standards and tensile fracture surfaces are examined using optical and Scanning Electron Microscope (SEM). The investigations proved that defect free sound joints with better mechanical properties are produced by taper cylindrical tool pin geometry under optimized process parameter values. It was experimentally found that the optimized FSW process parameter values namely 1.0 mm/min feed rate, 5 kN axial force, 1000 rpm of tool rotational speed along with a taper cylindrical pin profiled tool is preferable for FSW of AZ80A Mg alloy of 5mm thickness.Moreover, this experimental work revealed us that the taper cylindrical pin profiled tool fabricated sound, defect free welded joints along with better & improved mechanical properties when compared with other two pin profiles.

• Periodical: Materials Science Forum (Volume 866)
• Pages: 151-155
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.866.151
• Online since: August 2016
• Authors: V. Jaiganesh*, P.K. Nagarajan, P. Sevvel, J. Dhileep Kumar, S. Manivannan
• Keywords: AZ80A Mg Alloy, Feed Rate, Friction Stir Welding, Tensile Strength, Tool Geometry, Tool Rotational Speed

References

[1] E.A. Nyberg, A. Luo, K. Sadayappan and W.F. Shi, Magnesium for future autos, Adv Mater Processes, 166 (2008), p.35–37.

[2] Kulekci Mustafa Kemal, Magnesium & its alloys applications in automotive industry, Int J Adv Manuf Technol, 39 (2008), p.851–865.

DOI: 10.1007/s00170-007-1279-2

[3] V. Jaiganesh, P. Sevvel, Effect of Process Parameters in the Microstructural Characteristics and Mechanical Properties of AZ80A Mg Alloy during Friction Stir Welding, Transactions of the Indian Institute of Metals, 68 (2015), p.99–104.

DOI: 10.1007/s12666-015-0620-y

[4] P. Sevvel and V. Jaiganesh, Effect of Tool Shoulder Diameter to Plate Thickness Ratio on Mechanical Properties and Nugget Zone Characteristics During FSW of Dissimilar Mg Alloys, Transactions of the Indian Institute of Metals, 68 (2015), p.41–46.

DOI: 10.1007/s12666-015-0602-0

[5] K. Ganesa Balamurugan and K. Mahadevan, Investigation on changes produced by tool profile on tribological and mechanical properties of AZ31B magnesium alloy during friction stir processing, J. Manuf. Process., Vol. 15 (2013), p.659–665.

DOI: 10.1016/j.jmapro.2013.04.001

[6] P. Sevvel and V. Jaiganesh, Experimental Investigation on impact of Tool geometry & Material in joining Al 63400 Alloy using FSW Process, Applied Mechanics and Materials Vols. 592-594, (2014), pp.312-315.

DOI: 10.4028/www.scientific.net/amm.592-594.312

[7] M.M. Attallah and H.G. Salem, FSW parameters: A tool for controlling abnormal grain growth during subsequent heat treatment, Materials Science and Engineering A, 391 (2005), p.51–59.

DOI: 10.1016/j.msea.2004.08.059

[8] P. Sevvel and V. Jaiganesh, Characterization of mechanical properties and microstructural analysis of friction stir welded AZ31B Mg alloy thorough optimized process parameters, Procedia Engineering, 97 (2014), p.741–751.

DOI: 10.1016/j.proeng.2014.12.304

[9] P. Sevvel and V. Jaiganesh, Improving mechanical properties of friction stir welded AZ31B Mg alloy through axial force investigation, Applied Mechanics and Materials Vol. 591 (2014), p.11–14.

DOI: 10.4028/www.scientific.net/amm.591.11