TENSILE STRENGTH, SURFACE MORPHOLOGY, AND PRELIMINARY CORRELATION ANALYSIS OF AL-17SI ALLOYS IN FRICTION STIR WELDING PROCESSES

This study examines the intricate dynamics of the Friction Stir Welding (FSW) process utilized on the challenging hypereutectic composition of Al-17Si alloys, which obstructs effective metal flow and mixing. Higher rotating speeds stimulate greater mixing, but lower rotational speeds (600 rpm) cause uneven metal circulation around the tool. The benefits of increasing rotation speed to 1200 rpm for stress and strain outweigh the disadvantages for tensile strength. The ideal tensile strength is reached at lower feed rates (50mm/min), in conjunction with precise plunging depth, ensuring consistent extrusion and material flow to produce fine Si particles. Shear forces brought on by uneven metal flow around the tool pin are what give the fracture surface its distinctive knife-edge characteristics; sharper edges appear at higher feed rates. Additionally, this work makes use of correlation and regression analysis to shed light on the complex relationships between important process variables and material characteristics, highlighting the essential components that control the FSW process for Al-17Si alloys. To optimize the FSW process and subsequently enhance joint quality and performance, these findings emphasize the significance of carefully choosing process parameters such as tool rotation, feed rates, and plunging force.