Experimental Analysis and Optimization of Process Parameters on Friction Stir Welding of Aluminium (AA6061 T6) Alloy and ABS Plastic

Abstract: Friction stir welding is a solid-state joining process which can produce high quality welds of different components with either similar or dissimilar materials which are difficult to weld by conventional fusion welding techniques. Friction stir welding utilizes frictional heating combined with forging pressure to produce high strength bonds virtually free of heat affected defects, even in case of dissimilar metal to polymer sheets. Material joining are gaining a great deal of attention in several industries, in particular where a trade-off between reduced weight, improved performance and cost reduction is required. Combination of ABS plastic and aluminium alloys is an alternative solution to this problem. This project aims to weld plates of aluminium (AA6061 T6) alloy and ABS sheet in the lap joint configuration. Optimize the process parameters using Taguchi method for higher shear strength and shore D hardness and to analyse the effect of process parameters such as tool rotational speed, welding speed and shoulder diameter on the output parameters of friction stir weldment. The feasibility of the process was identified by means of microstructure and mechanical analysis.

Keywords: FSW, ABS plastic, AA6061 T6 Aluminum Alloy, Shore D hardness, Shear strength