ABSTRACT

Frictions stir welding is a relatively new solid state joining process. Over the past decade a lot
of research has been done on optimization of FSW process parameters by analysing the
microstructure and mechanical properties. Large studies were done on Friction stir welding
process based on process variables, effect of different tool geometries on weld quality and
effect on different materials. The main process parameters considered over past studies are
tool pin profile, spindle speed and tool traverse speed, but in all past research work only the
effect of any one process parameter is considered at a time. Only very few researches were
undertaken by considering all the above process parameters simultaneously. In this study,
three different tool pin were designed and the effect of these pin geometries on the
mechanical property of the joint were investigated. The process parameters like tool profile,
tool rotational speed and traverse speed were considered simultaneously. The combined effect
of these process parameters are studied. The welded joints were analysed for tensile strength,
elasticity and micro-hardness. Taguchi method of design of experiment is used to optimize
the process parameters for maximum value of ultimate tensile strength and percentage
elongation for the weld joint.