Prediction of Microhardness Profil of Friction Stir Welded Joints of AA3003 Aluminum Alloy

Abstract

Friction stir welding is a recommended green process that can replace other assembly techniques. FSW process reveals good mechanical properties, good corrosion resistance and good economic value. For the purpose to evaluate combinations of operating parameters and estimating the welded joint quality, mathematical relationships were carried out using a design of experiment on three levels of rotational speed, feed rate and tool tilt angle. The models allow micro-hardness prediction in the different FSW joint zones of AA3003 aluminum alloy. The interaction of the factors shows that a decrease in rotational speed, angle of inclination and an increase in feed rate leads to a decrease in temperature and good microhardness. A ‘W’ shape profile of microhardness was shown cross the section, indicating an efficiency equal to 88% and 79% in the nugget and the heat-affected zone successively, compared to the base metal. Contrary any deviation of welding interval may cause various defect such as tunnel voids, ‘kissing-bond’ defects and crack-like root flaws.

Keywords

• Friction stir welding
• Mathematical relationships
• Microhardness
• Aluminum alloy