Effect of Tool Pin Profile and Welding Parameters on Friction Stir Processing Zone, Tensile Properties and Micro-hardness of AA5083 Joints Produced by Friction Stir Welding
Ravindra S. Thube
Ravindra S. Thube,  Assistant Professor of Production Engineering Department, AISSMS COE, University of Pune, India.
Manuscript received on May 15, 2014. | Revised Manuscript received on May 26, 2014. | Manuscript published on June 30, 2014. | PP: 35-40  | Volume-3, Issue-5, June 2014.  | Retrieval Number:  E3077063514/2013©BEIESP

Open Access | Ethics and Policies | Cite
© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)

Abstract: AA5083 aluminium alloy has gathered wide acceptance in the fabrication of light weight structures requiring a high strength to weight ratio. Compared to the fusion welding processes that are routinely used for joining structural aluminium alloys, friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand the effect of tool speed (rpm) and tool pin profile on Friction Stir Processing (FSP) zone formation in AA5083 aluminium alloy. Friction stir welding between 5083 aluminium alloy plates with a thickness of 2.5 mm was performed. Five different tool pin profiles (straight cylindrical, tapered cylindrical, triangular, square and cone) have been used to fabricate the joints at three different rotational speeds i.e. 900, 1400 and 1800 rpm under a constant traverse speed of 16 mm/min. The formation of FSP zone has been analysed macroscopically. Tensile properties of the joints have been evaluated and correlated with the FSP zone formation. From this investigation it has been found that the tool pin profiled designs had little effect on heat input and tensile properties, weld properties were dominated by thermal input rather than the mechanical deformation by the tool for the plate thickness of 2.5 mm. straight cylindrical pin profiled tool produces mechanically sound and metallurgically defect free welds compared to other tool pin profiles.
Keywords: AA5083 aluminium alloy, Friction stir welding, macrostructure, Micro-hardness, Tensile properties, Tool pin profile.