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EXPERIMENTAL ANALYSIS ON ALUMINUM ALLOY 5083 WELDMENTS USING PULSED TIG AND FRICTION STIRE WELDING PROCESS

Prakash Singh, Madhur Srivastava


This study presents some research on the use of friction stir welding (FSW) and pulsed tungsten inert gas (PTIG) for the welding of aluminium alloy AA5083. Investigations into the mechanical, microstructural, and chemical characteristics of the weldments were conducted through both individual and comparative examinations of various welding methods. The review of the literature indicates that PTIG welding and FSW operations on AA 5083 material are less common. Additionally, there isn't much information on the comparison research between PTIG and FSW on AA 5083 in the previously published work. The optimal PTIG and FSW process parameters are recommended by this study effort in order to weld stronger weldments. Current is provided in a sinusoidal pattern at a regular frequency from a lower level to a higher level during PTIG welding. The current's lower level, known as back current, creates a steady arc. Peak current is a higher level current that provides superior penetration and bead shape. The resistance provided during the welding process determines which filler material is used in PTIG. The solidus state welding procedure known as FSW uses a spinning cylindrical tool made up of a profiled pin and shoulder. The tool in this procedure spins and is gradually inserted into the margins of the two weld plates. Process variables and mass flow rate affect how much heat is generated in FSW. Three chosen process parameters were the basis for complete factorial experiment designs in both welding processes. We carried out a total of 27 trials in both welding procedures, holding two parameters constant and altering one. In this work, 4 mm of AA 5083 alloy is employed as the base material. The test specimens were created in compliance with industry standards for welding. Both weld techniques employed the same material and weld samples. Three welding parameters are chosen for PTIG welding: filler rod diameter, gas flow rate, and welding current. In this investigation, an ER 5356 electrode with three diameters—1.6 mm, 2.4 mm, and 3.2 mm—is employed. Three welding parameters are used for FSW welding: tool tilt angle, welding speed, and tool rotational speed. In this procedure, a Flat Tool H13 material with an 18 mm diameter and 3.7 mm length is made and used. In this study project, the following five mechanical and chemical characteristics of weldments are examined. Impact Energy (IE), Yield Strength (YS), Tensile Strength (TS), Micro Hardness (MH), and Percentage of Elongation (PE). The base metal TS was found to be greater from the trials than the TS and YS of the PTIG and FSW weldments. However, compared to PTIG tensile strength weldments, the TS and YS of FSW weldments are greater. Compared to PTIG, FSW welded samples had a greater percentage of elongation. Compared to PTIG joints, the average impact energy in FSW was somewhat higher, although it was lower than in base metal. This could have occurred as a result of FSW's superior stirring effect. Hardness was found to be somewhat enhanced at the weld location in FSW. Because of the welding heat during PTIG, the hardness in the weld zone was somewhat reduced. Based on all of the experimental research, it was shown that FSW welding performed better overall than PTIG welding.