International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 05 | May-2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 2492 Optimization of Process Parameters on Friction Stir Welding of AA2014 & AA6082 Aluminium Alloy J. Murali 1 , K.T. Thilagham 2 , P. Sundararaj 3 1 Department of Metallurgy, Government College of Engineering, Salem-636011 2 Assistant Professor, Department of Metallurgy, Government College of Engineering, Salem-636011 3 Associate Professor, Department of Metallurgy, Government College of Engineering, Salem-636011 ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - The joining of the different materials to take advantages of the properties of each. Here AA6082 aluminum alloys butt welded with AA2014 to get high weldmetal properties and corrosion resistance. Both the alloys are Non- weldable because of the poor solidification and porosity in fusion zone. It is evident that the Friction stir welding is possible for dissimilar welding. To optimize the process parameters to get the better mechanical and microstructural properties of dissimilar joints AA2014 and AA6082 by friction stir welding using design of experiments in Taguchi`s method. The considered process parameters were welding speed, tool rotation speed, tilt angle. In this study the process parameters were optimized and ranked of parameters based on the Signal to Noise Ratio values and the optimized welding parameters were found the tool rotational speed of 1000rpm, Travel Speed of 70mm/min and Tilt angle of 2 0 . An attempt was made to join the dissimilar aluminium plate of 6 mm thickness with conical tapered tool profile. The quality of the joint was evaluated by means of tensile strength and fracture surface analysis by SEM analysis. Key Words: Friction stir welding, tool rotational speed, welding speed, tilt angle, Taguchi method 1.INTRODUCTION The increasing demand for High strength weld in aerospace, automobile, and structural applications vast dissimilar applications are possible. These aluminum alloys are generally classified as non- weldable because of the poor solidification microstructure and porosity in the fusion zone. Also the loss in mechanical properties as compared to the base material is significant. FSW has many notable advantages over fusion welding in order to get good strength. In plate form AA 6082 in T651, T6 & T4. The plate in T651 given heat Solution Heat treated and artificially aged. Material has high strength such as 7Mpa. The alloys AA2014 and AA6082 both in T6 Heat treated condition. It was observed all the pins preferred were broken due to high rotational speed and load applied. Pin profile has been changed to withstand the load. Design of Experiments is used to get a specific procedure for welding using the parameters used for welding. Here Taguchi’s method of design of experiments with 9 number of experiments and to get the results with good confidence limit. Taguchi’s design of L9 orthogonal array was made for 3 levels and 3 factors. The factors selected are rotational speed, travel speed and tilt angle. The specimens were then prepared for FSW welding. Further which need to take the tensile test to do the optimization using Taguchi`s method and characterization studies Tensile test were carried out across the FSW welded samples and SEM analysis for optimized sample. 2. EXPERIMENTAL DETAILS 2.1 Material and sample preparation From the given aluminum plate material a portion of material was cut into the required dimension of 25 X 25 mm (1 inch. X 1 inch.) to get the chemical analysis result. As per the standards the chemical composition of AA2014 and AA6082 were given in Table 1 and Table 2. Then the purity of the given material is checked by Spectroscopy technique. Table -1: Chemical composition of AA2014 in weight % Si% Fe% Cu% Mn% Mg% Zn% Ti% Cr% Al% 0.681 0.193 4.171 0.635 0.597 0.076 0.051 0.003 Bal. Table -2: Chemical composition of AA6082 in weight % Si% Fe% Cu% Mn% Mg% Zn% Ti% Cr% Al% 1.160 0.169 0.035 0.540 0.831 0.002 0.017 0.005 Bal. The base material were cut into work samples of dimensions merely equal to 100 x 50 x 6 mm for the studies. They are being welded using conical tapered (HSS) pin profiles. Weldments of dimensions equals to 100x 100 x 6 mm were made by Friction stir welding. 2.2 Material and sample preparation Table -3: Process Parameters FACTORS LEVEL 1 LEVEL 2 LEVEL 3 Rotational Speed (rpm) 800 1000 1200 Travel Speed (mm/min) 70 80 90 Tilt Angle ( 0 ) 1 2 0 Experiments are performed to find the working levels of parameters. The levels are observed in experiments are shown in Table.3. It was chosen such a way that AA6082 in advancing side and AA2014 in retreating side so as to enhance corrosion behavior of AA2014.