M tech production final presentation of my student

1. Dissertation Guide: Prof. Sharad V. Gaikwad
Dept. of Mechanical Engineering,
WALCHAND COLLEGE OF ENGINEERING, SANGLI
(An Autonomous Institute)
“ Optimization of Process Parameters of Friction
Stir Welding of Aluminium and Brass.”
Presentation on,
By
Rohit Ramraje Deshmukh
Prn.No: 2017MTEMEPR021
S.Y. Mtech- Production
16 April 2023
Walchand College Of Engineering, Sangli
1

2.  Introduction
 Literature Survey
 Scope of Project Work
 Objectives
 Proposed Work
 Project Work Plan
 Experimental Work
 References
Contents
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3.  Friction Stir Welding (FSW) is a solid state
welding process for joining of similar or dissimilar
materials.
Fig 1 : A Schematic of FSW [1]
What is FSW ?
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4. • When rotating tool moves along the weld line the frictional heat
generated between wear resisting welding tool and material of
the workpiece causes the latter to soften the material without
reaching the melting point of workpiece material.
• In FSW a rotating non-consumable cylindrical, shouldered tool
with a profile probe is rotated and slowly plunged into the joint
line between two pieces butted together.
• The maximum temperature reached is of order of 0.8 of the
melting temperature of material.
Working Principle
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5. Advantages of FSW
• Fine recrystallized microstructure of weld is possible.
• Absence of Solidification cracking.
• No shielding gas is required for materials with low
melting points.
• No loss of alloying elements.
• Excellent mechanical properties in the joint area.
• No harmful emission.
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6. Applications of FSW
• Aerospace.
• Automotives.
• Rail industry.
• Container and fuel tank industries.
• It is used where weight reduction and cost saving is desired.
• Ship building and marine industries.
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7. Literature Survey
Author
/ Year
Paper name Tool Material Parameters Response
Variables
Remarks
S. A. P.
Quadri
et al.
/2017.
A Study of
Aluminum 6082
and Brass 319
Materials by
Friction Stir
Welding
Process.
HCHCr
SD - 18 mm
PD - 5 mm
SL - 70 mm
PL - 4.5 mm
Cutting Speed -
710,900,1120
rpm
Feed- 20mm/min
Tilt Angle – 1°
Depth of Cut- 4.5
mm
Tensile
Strength
• Al-Al :
Maximum
Tensile
strength Occur
at 900 rpm is
173.196 Mpa.
• Brass-Brass :
Maximum
Tensile
Strength occur
at 710 rpm is
231.360 Mpa.
B.
Parida
et al. /
2014.
Effect of Tool
Geometry on
Mechanical and
Micro-structural
Properties of
Friction Stir
Welding of Al-
SS310 Straight
Cylindrical
tool and
Tapered
Cylindrical
Profiles.
Cutting Speed-
1400 rpm,
Feed – 112
mm/min
Tool Plunge Force
– 6300 N
Tensile
Strength
• Strength and
ductility of SC
tool profile tool
shows better
result than TC
profile tool.
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8. V. Prasanna
and K. Shilpa.
/ 2016.
Paper on
FSW process
on Al 6061-
Brass
(CuZn30).
H13 Tool
Steel.
SD- 25 mm
PD- 6 mm
PL- 3.6
mm
Cutting
Speed- 710-
1120 rpm
Feed- 10-110
mm
Offset- 1 mm
P. Depth- 3
mm
Tensile
Strength
Brass has high
strength than
aluminum.
H. Rawal et
al. / 2016.
Effect of
Process
Parameters
of FSW on
Al-6061.
Tool Steel
with
Cylindrical
Probe
SD- 18 mm
PD- 6 mm
PL- 5.7mm
Cutting
Speed-
700,800,900
rpm
Feed-
18,29,45
mm/min
Tensile
Strength
At 900 rpm, 18
mm/min feed ie.
With higher speed
and lower feed
combination gives
maximum tensile
strength.
V. Prabhakar
and G. reddy
/ 2018.
Effect of
Shoulder
Diameter
and Pin
profile on
Mechanical
properties of
Al-6061 Alloy
Tool Steel Tool profile:
Plain Tapered
and Steped
tapered
Speed: 900-
1800 rpm
Feed: 40-125
mm/min
Surface
Roughness
Minimum surface
roughness value
occur with plain
tapered profile
tool as compared
to stepped
tapered profile
tool.
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9. Patel et.al
/2016
Influence of Tool
Pin Profile and
Welding
Parameter
on Tensile
Strength of
Magnesium Alloy
AZ91 during
FSW
SD- 18
mm
SL- 20
mm
PD- 6 mm
PL-
5.8mm
SL- 25
mm
Tool Profile-
TSCP,
TSP,SC
Rotational
speed- 710-
1400 rpm.
Welding
Speed- 28-40
mm/min.
Tensile
Strength
High Tensile
Strength is
obtained
with TSCP
profile, 710
rpm speed
and 28
mm/min
welding
speed.
Laxminaray
ana et.al/
2014
Influence of
Process And Tool
Parameters on
Friction
Stir Welding
H13 Tool
Steel
SD- 19mm
Pin length-
2-3.5 mm
PD- 6.35
mm
Tool profile-
SC, TSC.
Rotational
speed- 2000
rpm,
Feed- 12
mm/min.
Reactivity of
tool material,
Effect of heat
generation
on tool.
pin cross-
sectional
geometry
and surface
features such
as threads
influence the
heat
generation
rates
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10. Scope of Project Work
• It was observed that most of the times less strength of
weld joint is achieved at the bottom side of weld with the
use of single shouldered cylindrical profile tool.
• From the literature it was found that a lot of research on
friction stir welding of aluminum and brass is done, but
the most suitable tool profile for joining of Al-Brass
component is not fully disclosed.
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11. The objectives of proposed study are :
1. To identify and study the effect of different
process parameters on mechanical properties of
FSW joints.
2. To select the parameters and their levels for
experimentation purpose and to perform the
array of experiment using standard orthogonal
array.
Objectives
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12. 3. To select the tool material and manufacture
the tool and tool profile for preparation of
weld joints.
4. To optimize the process parameters for
various mechanical properties using Taguchi
Method.
i. Tensile Strength.
ii. Micro-hardness.
iii. Percentage Elongation.
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13. • To study the effect of different process parameters on FSW joint plates
and their selection.
• Design of experiment using taguchi method.
• To Study the different tool materials and tool profiles and
manufacturing of tool.
• Conduct the experiments and preparation of standard specimens for
testing the tensile strength, micro-hardness and percentage elongation.
• Result analysis, validation and confirmation of results and preparing
drafts for publications.
• Report writing.
Proposed Work
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14. Project Work Plan
Planned Activity
Executed Activity
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Work Activity June 2018 July Aug Sep Oct Nov Dec Jan 2018 Feb Mar Apr May June 2019
Problem identification
Literature Survey
Selection of process parameters
Design of Experiments
Selection of Tool Material and Manufacturing
of Tool
Conduct trial and selection of parameters
values and main Experiment using DOE
Analysis and Determination of optimum
parameters
Validation and Confirmation of Results
Preparation of draft for Journals and
Conferences
Report writing

15. Experimental Work
 The FSW includes mainly following process
parameter’s.
• Spindle Speed
• Feed Rate
• Insertion Depth
• Welding Pressure
• Tool Geometry
• Material Flow Behavior
• Axial Force
• Preheating and Cooling
• Dwell Time
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16. Material Selection
• The FSW of aluminum joints has wide applications in Aerospace,
Automotive, Rail industry, Container and fuel tank industries.
• It is also used where weight reduction and cost saving is desired.
Ship building and marine industries.
• Brass is used in marine service owing to its corrosion resistance,
hardness and toughness. A characteristics application is to the
protection of ships bottom.
• Material Dimension:
i) Aluminum : 100 * 60 * 5 mm
ii) Brass : 100 * 60 * 5 mm
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17. Selection of Process Parameters
• Excessive spindle speed will cause premature tool wear, breakages and cause tool
chatters all of which can lead to potentially dangerous condition.
• FSW can be performed with tool of a simple geometry yet having good mechanical
properties .Advanced tool design provides intensified material flow in the stirred
zone and better weld quality
• So the selected major process parameters as per literature for this project Study are
i) Spindle Speed (rpm)
ii) Dwell Time (sec)
iii) Feed Rate (mm/min)
iv) Pin Profile
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18. Tool Material and Pin Profiles
• Tool materials are playing an important role in FSW because it purely depends on the
properties of the base material to be welded. The properties like melting point, strength,
hardness, toughness.
• The commonly used tool materials are
i) Tool Steels
ii) Nickel- and Cobalt-Base Alloys
iii) Tungsten Carbides
Fig : Basic FSW Tool Pin Profiles
Fig 2 : Tool after Hardening
Treatment
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19. Tool Development
• Tool design influences heat generation, plastic flow, the power required, and the
uniformity of the welded joint.
• Pin length depends of material sheet thickness (0.1 to 0.5 mm less than sheet
thickness). Pin width/diameter depends of pin length (pin diameter is equal or
greater than pin length).
• According to plate thickness (5mm) we have selected pin-probe length as 4.5
mm (effective length 4.8 mm), and as per standards pin-probe diameter is
nearly equal to pin-probe length which is 5mm.According to design standards
ratio of shoulder diameter to pin probe diameter is nearly 3 to 4, so the shoulder
diameter of tool is kept 20 mm. Taper given to the shank to hold the tool in tool
holder of vertical machining centre.
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20. Schematic Diagram of FSW Tool
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21. CATIA Drawing of Tool
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• Two types of pin profiles are selected for welding of aluminum
and brass
a) Straight Cylindrical b) Tapered Cylindrical

22. Experimental Setup
 VMC milling machine (MAXMILL PLUS +)
Specification:
• Maximum Travel : X-600, Y-450, Z-500 mm
• Spindle Speed Range : 100-8000 rpm
• Work table Size : X-700 mm, Y-420
• Axial Motor Power : 1.48/3.77 K-watt
Fig 3 : Experimental Setup.
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23. Design of Fixture
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Fixture design should be,
• It should able to arrest all degrees of freedom of the plates to
be joined.
• It should have sufficient strength to withstand the forces
during welding operation.
• It should made from the material which having the high
melting point so that possibility of sticking the plates to the
fixture after welding should be avoided.

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• The MS plate of size 25 * 18 cm and thickness 10 mm is used for
manufacturing the fixture
• The holes are drilled according to width and length of plates for clamping
of whole fixture arrangement on VMC machine and clamping of plates to
be welded on fixture.
Fig 4 : Fixture arrangement for clamping the
plates.
Continued …

25. 16 April 2023 Walchand College Of Engineering, Sangli 25
a) Al-Al weld joint
• The trial experiment was carried out on
Al-Al plates with straight cylindrical
profiled tool with following input
parameters.
• Feed: 9 mm/min
• Spindle Speed: 700 rpm
• Dwell time: 20 seconds.
Continued …

26. 16 April 2023 Walchand College Of Engineering, Sangli 26
a) Al-Brass weld joint
• The trial experiment was carried out on
Al-Brass plates with straight cylindrical
profiled tool with following input
parameters.
• Feed- 19 mm/min
• Spindle Speed- 1200 rpm
• Dwell time – 60 seconds.
Continued …

27. Sr
No
Process Parameters Level 1 Level 2 Level 3
1 Pin Profile Straight
Cylindrical
Tapered
Cylindrical
-
2 Spindle Speed (rpm) 1000 1200 1400
3 Feed Rate (mm/min) 18 22 26
4 Dwell time (sec) 20 40 60
Table 1: Input Parameters and Their Levels
Design of Experiment
• DOE deals with planning, conducting, analysing and interpreting controlled tests to
evaluate the factors that control the value of a parameter or group of parameters.The major
factors affecting FSW process parameters and their levels are shown in following table.
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28. Experiment no Pin Profile Spindle Speed (rpm) Feed Rate (mm/min) Dwell Time (sec)
1 Straight Cylindrical 1000 18 20
2 Straight Cylindrical 1000 22 40
3 Straight Cylindrical 1000 26 60
4 Straight Cylindrical 1200 18 20
5 Straight Cylindrical 1200 22 40
6 Straight Cylindrical 1200 26 60
7 Straight Cylindrical 1400 18 40
8 Straight Cylindrical 1400 22 60
9 Straight Cylindrical 1400 26 20
10 Tapered Cylindrical 1000 18 40
11 Tapered Cylindrical 1000 22 20
12 Tapered Cylindrical 1000 26 40
13 Tapered Cylindrical 1200 18 40
14 Tapered Cylindrical 1200 22 60
15 Tapered Cylindrical 1200 26 20
16 Tapered Cylindrical 1400 18 40
17 Tapered Cylindrical 1400 22 20
18 Tapered Cylindrical 1400 26 40
L18 Orthogonal Array
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29. • Three Response variables has selected as follows,
1. Tensile Strength (MPa)
2. Percentage Elongation
3. Micro-hardness
• Minitab software will be used for design of experiments.
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30. Tungsten Carbide Tool
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Fig 5.3 : a) Straight Cylindrical b) Tapered Cylindrical
 Rockwell Hardness : 85 HRC .

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Fig 5.6 : Experimental Setup Fig 5.5 : Fixture Arrangement For Clamping
The Plates
Fig 5.7: Welded
Aluminium-brass
Plates
Fig 5.8: Cut Parts For
Specimen Preparation

32. Preparation of Tensile Specimens
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• The tensile test specimens are prepared as per American Standards for Testing and
Materials (ASTM) on conventional milling machine.
• Gauge length : 60 mm
• Gauge width : 20 mm
Fig 5.11: Tensile Testing Specimens as Per ASTM
Standards

33. Tensile Testing
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• The tensile testing of specimens are carried out on UTM machine.
Fig 5.12: UTM Machine Exp. No 14: Stress-Strain Graph

34. Micro-hardness Specimens
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• The micro-hardness specimens are cut with dimensions 5 mm x 15 mm x 10 mm
and cold mounting material is used to make the specimens.
Fig 5.13: Micro-hardness Specimens Fig 5.20 Vickers Hardness Tester Machine.

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Experiment
no
Pin Profile Spindle Speed
(rpm)
Feed Rate
(mm/min)
Dwell Time
(sec)
Tensile
strength
(MPa)
% elongation Micro-
hardness in
weld zone
(VHN)
1 Straight
Cylindrical
1000 18 20 11.589 1.33 55.48
2 Straight
Cylindrical
1000 22 40 7.839 1.19 57.65
3 Straight
Cylindrical
1000 26 60 6.638 1.02 42.616
4 Straight
Cylindrical
1200 18 20
10.530
0.323 76.12
5 Straight
Cylindrical
1200 22 40 23.494 0.950 60.14
6 Straight
Cylindrical
1200 26 60 16.825 1.75 40.54
7 Straight
Cylindrical
1400 18 40 8.283 1.5 60.66
8 Straight
Cylindrical
1400 22 60 5.442 1 56.70
9 Straight
Cylindrical
1400 26 20 7.116 1.33 51.97
Experimental Results

36. 16 April 2023 36
Experiment
no
Pin Profile Spindle Speed
(rpm)
Feed Rate
(mm/min)
Dwell Time
(sec)
Tensile
strength
(MPa)
% elongation Micro-
hardness
(VHN)
10 Tapered
Cylindrical
1000 18 40 14.891 1.36 47.25
11 Tapered
Cylindrical
1000 22 20 12.606 1.33 62.80
12 Tapered
Cylindrical
1000 26 40 21.385 1.53 47.98
13 Tapered
Cylindrical
1200 18 40 20 1.33 60.66
14 Tapered
Cylindrical
1200 22 60 42.599 1.5 46.90
15 Tapered
Cylindrical
1200 26 20 33.732 0.667 29
16 Tapered
Cylindrical
1400 18 40 7.920 1.833 53.75
17 Tapered
Cylindrical
1400 22 20 40.296 1.166 86.72
18 Tapered
Cylindrical
1400 26 40 35.414 1.515 49.44
Continued….

37. Analysis of Experimental Results
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• Tensile Strength (Larger the better)
The main effect plot for means for the tensile strength is obtained as shown
in the Fig 5.14. It gives individual effect of process parameters on tensile strength.
Fig 5.14 : Main Effect Plot for Means for Tensile Strength.
Pin Profile Spindle Speed(rpm) Feed Rate (mm/min) Dwell Time (sec)

38. SN Ratio Graph
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Pin Profile Spindle Speed (rpm) Feed Rate (mm/min) Dwell Time(sec)
Fig 5.15 : SN Ratio Graph for Tensile Strength
• Optimum parameters for tensile strength are : Pin profile is TC, spindle speed is
1200 rpm, feed rate is 22 mm/min and dwell time is 40 sec.
• The value of P < 0.05 for pin profile (TC) hence this is the most influencing
parameter.

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• Percentage Elongation (Smaller the better):
The main effect plot for mean for the percentage elongation is obtained as shown in
the fig 5.16. It gives individual effect of process parameters on percentage elongation.
Fig 5.16 : Main Effect Plot for Means for Percentage Elongation
Pin Profile Spindle Speed (rpm) Feed Rate (mm/min) Dwell Time (sec)

40. SN Ratio Graph
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Pin Profile Spindle Speed(rpm) Feed Rate (mm/min) Dwell Time (sec)
Fig 5.17 : SN Ratio Graph For Percentage Elongation
• Optimum parameters for percentage elongation : Pin profile is SC, spindle
speed is 1200 rpm, feed rate is 18 and dwell time is 20 sec.
• The value of P < 0.05 for dwell time hence this is the most influencing
parameter.

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• Micro-hardness (Larger the better):
The main effect plot for means for micro-hardness is obtained as shown in the
following fig.5,16. It gives individual effect of process parameters on micro-hardness.
Pin Profile Spindle Speed(rpm) Feed Rate (mm/min) Dwell Time (sec)
Fig 5.16 : Main Effect Plot for Micro-hardness

42. SN Ratio Graph
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Pin Profile Spindle Speed(rpm) Feed Rate (mm/min) Dwell Time (sec)
Fig 5.19 :SN Ratio Graph For Micro-hardness
• Optimum parameters for micro-hardness are : Pin profile is SC, spindle speed is
1400 rpm, feed rate is 22mm/min and dwell time is 20 sec.
• The value of P < 0.05 for feed rate hence this is the most influencing parameter.

43. Validation
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• From GRA and from S/N ratio graph the
optimum process parameters are:
• Pin Profile : Tapered Cylindrical (TC)
• Spindle Speed : 1200 rpm
• Feed Rate : 22 mm/min
• Dwell Time : 20 sec.
Fig 5.21: S/N Ratio Graph for GRG
Sr no Pin Profile Spindle
Speed (rpm)
Feed Rate
(mm/min)
Dwell Time
(sec)
Tensile
Strength
(Mpa)
%
Elongation
Micro-
hardness
1 TC 1200 22 20 33.73 0.973 53.43
Results of validation experiment

44. Conclusions
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• From the project work it is concluded that the tool steel material is not suitable
to carryout aluminium- brass welding because higher thrust and induced
temperature during welding and low hardness of tool material. So tungsten
carbide is suitable as a tool material.
• Tapered cylindrical tool profile gives the higher strength as compared to
straight cylindrical tool profile.
• The optimum set of parameters are : spindle speed is 1200 rpm, pin profile is
tapered cylindrical (TC) , feed rate is 22 mm/min and dwell time is 20 sec.
• The welding of aluminium- brass is difficult due to variation in melting points
of both materials hence strength of weld joint is lower as compared to the
base materials.
• Uniform mixing of both the material is difficult because the brass get
powdered as the tool plunges and move along the weld line.

45. References
1. Dayanand K., and A. Joshi G. " Friction Stir Welding on Dissimilar Metals
Aluminum Alloy to CuZn34 Brass." Imperial Journal of Interdisciplinary
Research, Vol.(3), pp. 2454-1362, 2017.
2. Quadri S. A. P., R. Suman, Mohiddin M. K. " A Study of Aluminum 6082 and
Brass 319 Materials by Friction Stir Welding Process " International journal of
Engineering Trends and Technology, Vol.(46), pp. 178-183, 2017.
3. Parida B. Mohapatra M. M. and Biswas P. " Effect of Tool Geometry on
Mechanical and Micro-structural Properties of Friction Stir Welding of Al
alloy.“ International Journal of Current Engineering and Technology, Vol.(2),
P-ISSN 2347-5161, 2014.
4. Prasanna V. and Shilpa " Paper on Dissimilar Materials by Friction Stir welding
Process." International Journal of Engineering Science and Computing,
Vol.(6), pp.2541-2543, 2016.
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46. 5. Rawal H. Tejnani C. Rakholiya D. Patil V. and Patel D. “ Effect of
Process Parameters by Friction Stir Welding.” International Journal
for Scientific research and development, vol.(4), PP. 1830-1834,
2016.
6. Prabhakar V. and Reddy G. S. “ Effect of Shoulder Diameter and Pin
profile on Mechanical properties of Al-6061 Alloy by FSW.”
international Journal of Engineering Development and Research,
Vol.(6), PP. 49-51, 2018.
7. Yadav V. D. and Bhatwadekar S. G. " Friction Stir Welding of
Dissimilar Material between AA6101 and Pure Copper."
International Journal of Engineering science and research
technology, Vol.(3), pp. 2277-9655, 2014.
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47. 8. Patel B. and Bhatt K. “Influence of Tool Pin Profile and Welding Parameter
on Tensile Strength of Magnesium Alloy AZ91 during FSW.” 3rd
International Conference on Innovations in Automation and Mechatronics
Engineering, vol (23),pp. 558 – 565 ,2016.
9. Patel B. and vasava A.“ Review paper on friction stir welding.” International
Research Journal of Engineering and Technology, vol (3),pp.505-510, 2016.
10. Laxminarayana P. and Pasha M. “Influence of process and tool parameters on
friction Stir welding.” International Journal of Applied Engineering and
Technology, vol.(4),pp. 54-65, 2014.
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