In this research article, the mechanical properties and microstructure analysis ofFriction Stir Welded (FSW) of dissimilar aluminium alloys AA8011-AA6082 were evaluated. The FSW tool with taper ...cylindrical shape of H13 steel was selected to fabricate the weld joints between the dissimilar alloys. In this regard, three different rotational speed tools, three welding speeds and an unvarying axial load of 7 kN are used in this investigation. The tool rotational speeds are 800 rpm, 1000 rpm and 1200 rpm. The tool travelling speeds are 25mm/min, 30 mm/min and 35 mm/min. These constraints are used to generate frictional heat and interface into the soft range where the joining process can take place between the two materials. The mechanical tests were carried out on the weld joints. Microstructure analysis, tensile and hardness tests were considered by changing the tool rotating speed, welding speed and maintaining a constant axial force during material joining process. The micro hardness of the FSW weld joints in the stir zone increased to increase the tool rotational speed as well as to maintain a low range of welding speed during material joining process. The micro hardness of the stir zone in the FSW weld joints is increased as to reduce the welding speed. It was found that the highest value of the tensile strength in the joints is made-up of using the taper-shaped tool at 800 rpm, welding speed of 35mm/min and unvarying downward force of 7kN. These identified parameters give sufficient mechanical properties and fewer defects in weld joints such as tensile strength of 68 N and micro hardness of 42 Hv. The tensile and hardness tests values are examined by the part of mechanical characterization and the values are correlated to recognize the superiority of the weld joint.
In this work, an alloy is formulated with Aluminium alloy 7075 reinforced with varying % of weight of Titanium Carbide powders. The alloy was stir casted and was evaluated for mechanical properties ...such as tensile strength, hardness and impact strength. Titanium Carbide was mixed to aluminium at 4% and 8% in weight proportions and was compared to the mechanical properties of aluminium alloy 7075. The developed alloy with 4% TiC inclusion posted higher tensile strength of 183 N/mm2 and Impact strength of 231.43 J/mm2. Simultaneously for alloy with 4% TiC inclusion, the % of elongation and hardness was improved. The hardness and percentage of Elongation was maximum for alloy with 8% TiC. SEM images shows uniform distribution of TiC . Pits and agglomeration has been identified with the casted surface.
In this paper, the effects of axial force on the mechanical properties of AZ31B magnesium alloy flat plates during the Friction Stir Welding (FSW) process were investigated by carrying out the ...tensile tests as per the American Society for Testing and Materials (ASTM) E8M-11 standards. The tensile test results indicated that the increase of the axial force greatly improved the tensile shear load (TSL) of the friction stir welded joints at a constant tool rotational speed of 800 rpm and welding speed of 50mm/min. Sound lap joints with low distortion, lack of cavity and high tensile strength were successfully obtained with an axial force of 5kN. However, the TSL of the friction stir welded joints decreased when the axial forces were 3kN and 4kN with the same constant tool rotational and welding speed.
In this paper, a detailed experimental investigation was carried on the impact of the effects of tool pin and shoulder diameter in joining the Al 63400 aluminium alloy using FSW process. Flat plates ...of 6 mm thickness have been selected as the base material for obtaining single butt welded joints. The tool materials used for joining these base material plates are High Speed Steel (HSS) and High Chromium High Carbon Steel (HCHCr). This paper experimentally investigates and suggests the appropriate, suitable tool material & tool geometry for producing good quality welds in joining of Al 63400 alloy using FSW process.
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.
An investigation was conducted to find out the influencing role of the geometry of the FSW tool on the tensile strength, corrosion resistance, wear rate of the wrought AZ80A Mg alloy joints during ...the FSW process. FSW tools with two uniquely different geometries, namely stepped cylindrical shoulder tool and stepless cylindrical shoulder tool were employed at different combinations of speeds of rotation and traversing speed. Comprehensive observations & investigations were also carried out regarding the tensile strength, wear losses & corrosion resistance of the fabricated joints. The joints fabricated using stepped cylindrical shoulder tool exhibited appreciable tensile strength values at combinations of higher traversing feeds and low values of rotational speeds of the FSW tool. At the same time, the joints possessing fine sized refined grains in their nugget zone have been found to exhibit higher wear losses.
A wind turbine performs the function of converting the energy (kinetic) derived from the wind into another form of energy (mechanical) which is employed for the purpose of driving the generator which ...in turn generates electricity from this mechanical energy. The most common types of windmills employed in practice include horizontal and vertical axis wind mill. These windmills are fabricated in different structures for producing electricity. The main objective of this paper is to design an innovative eco friendly windmill to overcome the various difficulties existing in conventional windmills. In conventional windmills, the propeller rotation depends on the velocity of wind flow in the environment. But in this paper, we have fabricated an innovative eco friendly windmill in which, the propeller rotation is increased four times for the wind velocity in the surroundings.
An investigation was conducted to find out the impact of the speed of rotation and pin profile of FSW tool on the microstructural characterisation & mechanical properties AZ80A magnesium alloy joints ...produced using FSW technique. FSW tools with completely three distinct pin profiles were at discrete speeds of rotation. The fabricated joints & their fracture surfaces obtained during tensile tests were subjected to microstructural & scanning electron microscopic (SEM) investigations. Comprehensive observations & investigational measurements were also carried out regarding the wear & hardness of the fabricated joints. The joints fabricated at 750 rpm using the taper cylindrical pin profiled tool exhibited high quality joints with better tensile strength, higher microhardness values and minimum wear.
SLM (selective laser melting) is a unique additive manufacturing process playing a vital component in building the Industrial revolution (industry 4.0), where the machine can produce the preferred ...parts faster and perfectly using metal powders. In the forthcoming era, there will be a possibility to fabricate products at an incomparable speed. The production of durable and efficient parts from distinct metals with unique mechanical and thermal properties utilizing advanced manufacturing processes leads to the development of the powder bed fusion process. Conventional manufacturing methods normally limit themselves with time and cannot react faster to the demand of the customers and it is highly impossible to fabricate parts with complex geometries together with high value of mechanical properties. At the same time, SLM technique offers some attractive advantages like eliminating the need for mold, no requirement for welding or riveting, thereby reducing the time of production and indirectly contributing to a cheaper production cost. In addition to this, the parts fabricated by SLM technique are found to possess high quality and found to exhibit desirable performance. Current changes in fibre optics and advancement in laser power sources also enables SLM to fabricate and to carry out research work with different metal powders. This review paper focuses in detail about the various challenges existing in SLM technique w.r.t fabrication of parts using alloys of various metals including aluminium, magnesium, titanium and steel. This paper also reviews the research investigations carried out by several researchers and brief descriptions about their findings.
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