Study of friction stir welding parameters in conventional milling machine for 6082-T6 aluminium alloy

Abstract

A conventional milling (CM) machine is capable of inducing the same axial force parameter as that of a friction stir welding (FSW) machine. In a CM machine, tool shoulder penetration, an alternate parameter instead of axial force of FSW machines, was used to carry out FSW joints. The process parameters such as spindle speed, welding speed, shoulder penetration, pin profile and shoulder profile at five levels were studied. With Taguchi orthogonal array, the process parameters were optimised to maximise the tensile strength of the FSW joint. From the investigation, it was found that the 1100 rpm spindle speed, hexagonal pin profile and 0.15 mm shoulder penetration reveals good results. Metallographic studies were carried out with a scanning electron microscope and energy dispersive x-ray spectrometer.

Keywords:

• Friction stir welding
• milling machine
• shoulder penetration
• aluminium alloy 6082-T6
• Taguchi method

Additional information

Notes on contributors

S Gopi

S. Gopi received his BE degree in Production Engineering from Madras University, Chennai, India, in 2001, and ME degree in Engineering Design from Anna University, Chennai, India, in 2007. He is currently an Assistant Professor at the Department of Production Engineering, Government College of Technology, Coimbatore, India. He is a budding research scholar in the area of welding, especially friction stir welding. He has published few papers in different journals and conferences at national and international levels. His current work covers welding techniques, element design and analysis, operation research, optimisation techniques, and industrial automation.

K Manonmani

K. Manonmani received her BE degree in Mechanical Engineering, ME degree in Engineering Design and PhD from Bharathiar University, India, in 1989, 1998 and 2007, respectively. She is currently an Associate Professor at the Department of Mechanical Engineering, Government College of Technology, Coimbatore, India. She has over 20 publications in different journals and conferences. Her current research includes welding techniques, especially high energy welding processes, and well as modelling of welding processes, vibration engineering, non-traditional optimisation, and finite element analysis.