Investigation on Effect of Strain Rate and Heat Generation on Traverse Force in FSW of Dissimilar Aerospace Grade Aluminium Alloys

The emergence of the aerospace sector requires efficient joining of aerospace grade aluminium alloys. For large-scale industrial practices, achievement of optimum friction stir welding (FSW) parameters is chiefly aimed at obtaining maximum strain rate in deforming material with least application of traverse force on the tool pin. Exact computation of strain rate is not possible due to complex and unexposed material flow kinematics. Estimation using micro-structural evolution serves as one of the very few methods applicable to analyze the yet unmapped interdependence of strain rate and traverse force. Therefore, the present work assessed strain rate in the stir zone using Zener Holloman parameter. The maximum and minimum strain rates of 6.95 and 0.31 s(−1) were obtained for highest and least traverse force, respectively.