Analyzing the Influence of Tool Profile on Friction Stir Process with Taguchi Optimization and Tungsten Nano Powder
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Abstract
Over the past decade, friction stir welding (FSW) has gained significant recognition for its versatility and has found numerous applications in industries such as automotive, shipbuilding and aerospace. A recent development in this field involves the integration of ceramic nanoparticles into FSW, leading to the localized formation of metal matrix composites (MMCs) along the weld line. This study aims to investigate the influence of tungsten nano powder on the weld nuggets of AA6082-T6 butt welds. To achieve this, a comprehensive analysis was conducted employing scanning electron microscopy, as well as microhardness testing. Modified Taguchi’s optimization was utilized for this study and developed an empirical relation in terms of output parameters. The investigation focused on two distinct pin profiles, namely straight cylindrical and square pins, to assess their impact on the weld. As attention was directed towards examining the distribution of dislocations, as well as the presence of intermetallic and reinforcing particles within the weld. Interestingly, the introduction of tungsten nano powder resulted in the dilution of numerous intermetallic particles from the base metal, leading to a higher multiplication of dislocations. Overall, this study sheds light on the effect of tungsten nano powder on the weld nugget of AA6082-T6 butt welds. Comparative analysis between the two pin profiles revealed that the square pin exhibited superior microhardness values.
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