1. OPTIMIZATION OF FRICTION STIR WELDING IN ALUMINIUM 6063-T6 AND MAGNESIUM ALLOYS Project guide : Dr.V. Jai ganesh Designation : Professor Project members: G.Naresh Kumar (11410114032) M.Lakshmaiya (11410114021) R.Mahesh Babu (11410114305) A.Ashwin karthik(11410114301)

2. INTRODUCTION INTRODUCTION FRICTION STIR WELDING  FSW is a solid state joining process in which the material that is being welded does not cause any defects.  Rotating probe provides friction heat and pressure which joins the material  The process of replacing the conventional riveting process is coined as FSW. 2

3. ABSTRACT  Aluminium 6063-T6 and magnesium alloys has gathered wide acceptance in the fabrication of the light structures required to high strength.  In this experimental work, an optimization has been carried out on aluminum6063-T6 and magnesium alloys 3

4. MACHINING PROCESS 4

5. OBJECTIVE  To enhance the process of joining, two different alloy materials.  To avoid conventional fusion techniques.  Welding can be done without producing toxic fumes  To weld aluminium alloys in any configuration  To avoid the use of filler materials 5

6. WORKING OPERATION WORKING OPERATION Probe which Stir the material Welded part Work piece 6

7. MATERIALS AND TOOLS IN FSW Copper and its alloys (PCBN) Plastics(viblade) Titanium and its alloys (M35) Magnesium alloys (HSS) Aluminium (HSS,HcHcr) 7

8. TOOLS IN FSW 3D-view TOOLS IN FSW 3D-view 8

9. TOOLS 9

10. HSS TOOL-SHOULDER DIFFERENCE 10

11. WORK PIECE-AL6063-T6 11

12. WELDABLE COMBINATIONS 12

13. CYCLIC OPERATION CYCLIC OPERATION Analysis of literatures Material selection Tool selection Machining operation Lab test &thesis work 13

14. FSW MACHINE FSW MACHINE 14

15. FIXTURE ANALYSIS 15

16. WELDED MATERIAL 16

17. Dissimilar Metals – Friction Welded 17

18. WORK EXPERIMENT AL6063-T6 Trial noTool profile Speed (rpm) Feed (mm/min) output 1 Cylindrical Pin 180050 Poor welding strength 2 Square pin 100050 Air gap and poor finish 3 Taper cylindrical 80030 Good surface finish 4 Square pin 80020 Excellent weld strength 18

19. WORK EXPERIMENT MAGNESIUM ALLOYS Trial noTool profileSpeed (rpm) Feed (mm/min) output 1 Square pin 100030 Good weld strength 2 Square pin 80030 Good weld strength 19

20. CAUSE AND EFFECT 20

21. SIGNIFICANCE Improved mechanical strength Reduced defect rate Reduces health hazards Less operator dependent Reduces distortion 21

22. APPLICATION Automobile: Bimetallic engine valve, universal joint yoke, gear hub etc. Aerospace: Turbine blade joining, seamless joining etc. Consumer: Hand tools, sports equipment Industrial: Spindles, tapers, tools Military Medical: Stainless steel joining of containers Marine: Shipping Industry Mining/Drilling: Twist drill etc. Hydraulic equipments 22

23. APPLICATIONS 23

24. APPLICATION 24

25. WORKING PROCEDURE 25 Material &tool selection Tool manufacturing Machining operation Lab test &thesis work

26. TENSILE SPECIMEN 26

27. TENSILE RESULT- AL6063T6 27

28. MICRO ANALYSIS 28 Thermal and stress created in the aluminum matrix(HAZ) Parrent material along with direction rolling(Mg2Si )

29. MICRO ANALYSIS 29 Shows the parent material and the nugget zone Complete nugget zone

30. TENSILE -MAGNESIUM 30

31. Tensile testing machine 31

32. CONCLUSION The following observations are made from the studies:  Thus the ultimate break load is different on using the square pin tool on aluminium and magnesium alloys  Good weld strength is at a speed of 800 rpm and 30mm/min for aluminum and magnesium alloys 32

33. REFERENCE Colgrove P.A. and Shercliff H.R.: ‘Development of Trivex friction stir welding tool Part 2 – three-dimensional flow modelling’. Science and Technology of Welding & Joining 2004, 9(3) 352-61. Ulysse P.: ’Three-dimensional modeling of the friction stir-welding process’ International Journal of Machine Tools & Manufacture 2002 42 1549–57. Cook G.E., Crawford R., Clark D.E. and Strauss A.M.: ‘Robotic Friction Stir Welding’. Industrial Robot 2004 31 (1) 55-63. Mills K.C.: Recommended Values of Thermo-physical Properties for Commercial Alloys. Cambridge, UK 2002. 33

34. ecofsw2014@gmail.com  To create a better communication between the team members and our guide we have created a common e-mail id  Reports,literatures are available in our common e-mail 34

35. PRESENTED PAPER ON FRICTION STIR WELDING AT NATIONAL CONFERENCE 35

36. IMAGES 36

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