Syed et al. 2023. Int. J.

Vehicle Structures & Systems, 15(6), 802-807

Int ernat i onal Journal of
ISSN: 0975-3060 (Print), 0975-3540 (Online)
doi: 10.4273/ijvss.15.6.12 Vehicle Structures & Systems
© 2023. Carbon Magics Ltd Available online at https://yanthrika.com/eja

Analyzing the Influence of Tool Profile on Friction Stir Process with Taguchi
Optimization and Tungsten Nano Powder
Karimulla Syeda, Md. Abid Alib, Kurre Prasanth Kumar Reddya,c and Boggarapu Nageswara Raoa
aDept.of Mech. Engg., Koneru Lakshmaiah Education Foundation, Deemed to be University, Guntur, Andhra Pradesh, India
bDept.of Mech. Engg., Lingayas Institute of Management and Tech., Vijayawada, Andhra Pradesh, India
cCorresponding Author, Email: kprasanthkumarreddy@gmail.com

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.

KEYWORDS:
Friction stir processing; Microstructure; Electron microscopy; Surface structure; Aluminum matrix composites

CITATION:
K. Syed, M.A. Ali, K.P.K. Reddy and B.N. Rao. 2023. Analyzing the Influence of Tool Profile on Friction Stir Process
with Taguchi Optimization and Tungsten Nano Powder, Int. J. Vehicle Structures & Systems, 15(6), 802-807.
doi:10.4273/ijvss.15.6.12.

one-of-a-kind grain limits are impacted by heat [2]. FSP

1. Introduction was made to overhaul the change of surface according to
the welding strategy in the solid state. A turning device
Friction Stir Welding (FSW) is a strong welding technique
that is non-consumable is used. The material is appeased
found by “The Welding Institute (TWI)” of the United
by the scouring action which produces adequate warmth
Kingdom in 1991. A couple of examinations have been
and gives adequate weight. Due to the stirring activity, the
coordinated to fabricate the exhaustion confrontation of
instrument pin is installed into the material accordingly
mix welds, to progress the superplastic and disintegration
passing on refined microstructure.
impediment properties of a couple of materials and to
In any machine, processes and parameters are the
make Metal Matrix Composites (MMCs) over the joining
most basic to consider. Therefore, in the current work,
of earthenware and/or nonceramic elements to the base
microhardness and TEM are considered. It is fundamental
material. The current work revolves around the
to appreciate the significant time frame status of SEM
assessment through scanning electron microscopy (SEM)
process to suggest future areas of work. A broad literature
and transmission electron microscopy (TEM) of the weld
survey has been done to find the state of the art at SEM
nugget of un-reinforced and developed models.
process. Energy Dispersive Spectroscopy (EDS) gives an
Therefore, the instruments regulating the scattering of the
effective manufacturing method that enables the making
structure up nanoparticles and partitions in weld nuggets
of parts made of hard materials with tangled estimations
during Friction Stir Processing (FSP) can be recognized.
that are difficult to convey by standard machining
An acceleration reduction of FSP instrument might also
measures. A few attempts have been made to improve the
be a reason for the deterioration in the particle size of the
performance of FSP boundaries. Dolatkhah et al [3]
stir zone in the friction stir, which took care of metal
observed microstructural characterization and
particles [1]. Usually, cross speed influences the
fractography of joints by SEM and process parameters,
microstructure and results in smaller than expected
three feeds and three rotational speeds were utilized.
hardness. High cross-speed impact microhardness. The
Elangovan et al [4] examined the impact of tool profile
development of metal powder initiates extending the wear
and shoulder diameter on the development of FSP of
resistance of the material. The central burden is the force
Al6061 aluminum alloy. Padmanaban et al [5] observed
circling back to FSP gadget. A stir zone is the area where
the tool pin profile in friction stir weld AZ31B magnesium

802
 Syed et al. 2023. Int. J. Vehicle Structures & Systems, 15(6), 802-807

alloy. Karakizis et al [6] carried out microhardness and presented in Table 3. It is seen that percentage
tensile testing, for determining the impact of SiC and TiC contribution of speed, feed, dummy (D1) and the dummy
nano powders on the weld nugget using multiple (D2) variable on the hardness for straight cylindrical pin
rotational speed and traverse speed. The tool used was are 68.95%, 0.06%, 17.05% and 13.94% respectively, for
cylindrical with left-hand threaded AA6082-T6 material. square pin are 80.34%, 7.97%, 8.00% and 3.68%
Balakrishnan et al [2] and Sathiskumar et al [7] respectively. The percentage contribution of the dummy
studied the surface characteristics of composites by variable (D1 & D2) on the hardness for straight cylindrical
utilizing the FSP and the impact of tool parameters and pin and square pin are 17.05%, 13.94% and 8.00%, 3.68%
microhardness. Zhao et al [8] studied FSP with B4C respectively.
particles to enhance the surface modification of 6061 Table 1: Levels of FSP process parameters
aluminum alloy. Ikumapayi et al [1] used household waste
wood fly ash and industrial waste coal fly ash as a vowing Parameter Level-1 Level-2 Level-3
and possible substitution to metallic powders for Rotational speed (rpm) 700 1200 1700
reinforcements and corrosion. Tool profile used was Transvers feed (mm/s) 50 90 130
tapered cylindrical. The material used is AA 7075. Dummy D1 d1 d2 d3
aluminum-based composites that were reinforced with Dummy D2 d1 d2 d3
different materials to test their mechanical properties, Table 2: Test data of performance indicator (Hv)
strength and corrosion resistance. Tool pin profile used
was threaded straight cylindrical and material used was Speed Feed Dummy Cylindrical Square
Al203 [5, 9]. An examination was carried out on different 1 1 d1 d1 171.254 242.215
MMCs. It was found that metal breaks reliably incited for 1 2 d2 d2 175.361 246.568
the hour of the organization crossing spotlights and 1 3 d3 d3 176.532 248.967
subject to the holding of the particle. A plastic movement 2 1 d2 d3 181.210 254.876
of metallic body among an exterior tool and the surface 2 2 d3 d1 179.226 271.532
has begun with the help of FSP. The device roots the 2 3 d1 d2 178.426 270.128
dislocation of plasticized substance all over the place and 3 1 d3 d2 176.335 268.214
mergers of particles along with the plasticized material in 3 2 d1 d3 174.531 266.226
the course of passage [10]. 3 3 d2 d1 174.331 265.265
Table 3: ANOVA and the significance of process parameters
2. Experimentation Parameter 1st 2nd 3rd SSq % Contribution
Welded plates are created using 6082-T6 aluminum Hardness (Hv) for straight cylinder pin; grand mean = 176.36
composite. Their dimensions are 150mm×75mm×6mm. Speed 174.38 179.62 175.07 48.66 68.95
Chemical Vapor Deposition (CVD) is used to make Feed 176.27 176.37 176.43 0.04 0.06
tungsten (W) nano particles. A ‘U’ shaped groove was D1 174.74 176.97 177.36 12.03 17.05
made by utilizing a vertical milling machine. As the D2 174.94 176.71 177.42 9.83 13.94
groove is filled with nano particle, the un-reinforced tool Hardness (Hv) for square pin; grand mean = 259.33
will make a pass on the plate to keep the nano particles Speed 245.92 265.51 266.57 811.58 80.34
tight. Taguchi’s design of experiments suggests few Feed 255.10 261.44 261.45 80.54 7.97
experiments. From the acquired test data, there is a D1 259.52 255.57 262.90 80.86 8.00
possibility to generate the information for the full factorial D2 259.67 261.64 256.69 37.22 3.68
design of experiments. In the present problem, 3 SLM
process parameters are considered assigning 3 levels to Let 𝜓 be the performance response and 𝜓̑ is its
each parameter. This corresponds to 27 experiments for estimate for the SLM process parameters (𝑞𝑖 , 𝑣𝑗 , ℎ𝑘 , 𝑑𝑙 )
the full factorial design of experiments. Taguchi’s design varying the subscripts 𝑖, 𝑗, 𝑘, 𝑙 from 1 to 3. Designating
of experiments recommends only 9 tests as per L9 𝜓(𝑞𝑖 ), 𝜓(𝑣𝑗 ), 𝜓(ℎ𝑘 ) and 𝜓(𝑑𝑙 ) as mean values of 𝜓
orthogonal array [11-17]. Modified Taguchi’s for 3 SLM corresponding to the 𝑖 𝑡ℎ level of 𝑞, 𝑗𝑡ℎ level of 𝑣, 𝑘 𝑡ℎ level
process parameters with assigned 3 levels to each of ℎ and 𝑙 𝑡ℎ level of 𝑑. The grand mean of 𝜓 is designated
parameter, the min. test runs (𝑁𝑇𝑎𝑔𝑢𝑐ℎ𝑖 ) required is [18], by 𝜓𝑚𝑒𝑎𝑛 for the 9 test runs. Following the additive law,
𝑁𝑇𝑎𝑔𝑢𝑐ℎ𝑖 = 1 + 𝑛𝑝 × (𝑛𝑙 − 1) = 1 + 3 × (3 − 1) = 7 (1) estimate 𝜓̑ for the specified (𝑞𝑖 , 𝑣𝑗 , ℎ𝑘 , 𝑑𝑙 ) is,
Here, 𝑛𝑝 is the no. of SLM process parameters. 𝑛𝑙 , is the 𝜓̑ = 𝜓(𝑞𝑖 , 𝑣𝑗 , ℎ𝑘 , 𝑑𝑙 ) = 𝜓(𝑞𝑖 ) + 𝜓(𝑣𝑗 ) + 𝜓(ℎ𝑘 ) +
no. of levels assigned to each SLM process parameter. For 𝜓(𝑑𝑙 ) − 3 × 𝜓𝑚𝑒𝑎𝑛 (2)
𝐿9 orthogonal array, substitution of the number of test
For the specified (𝑞𝑖 , 𝑣𝑗 , ℎ𝑘 ), Eqn. (3) reduces to,
runs, 𝑁𝑇𝑎𝑔𝑢𝑐ℎ𝑖 = 9 and the levels, 𝑛𝑙 = 3, one can find 𝑛𝑝 =
4. That means 4 factors can be accommodated in 9 test 𝜓̑ = 𝜓(𝑞𝑖 , 𝑣𝑗 , ℎ𝑘 ) = 𝜓(𝑞𝑖 ) + 𝜓(𝑣𝑗 ) + 𝜓(ℎ𝑘 ) − 2 ×
runs, without loss of generality, [19-22]. Hence, 𝜓𝑚𝑒𝑎𝑛 (3)
fictitious/dummy parameter (d) is considered as presented Estimates from Eqns. (2) and (3) provide different 𝜓
in Table 1. Table 2 presents the levels of the SLM process values, whose deviation is 𝜓(𝑑𝑙 ) − 𝜓𝑚𝑒𝑎𝑛 . Three
parameters for the 9 test runs. deviations can be found for the three levels (l = 1, 2, 3).
Additive law [18] provides the estimates of Superimposing the minimum and maximum deviation
performance indicators from the mean values of analysis values to the estimates using Eqn. (3), the range of
of variance (ANOVA) with sum of squares (SSq) as estimates is arrived. Table 4 presents the estimates of

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 Syed et al. 2023. Int. J. Vehicle Structures & Systems, 15(6), 802-807

performance responses. Test data of performance microhardness was measured using a METCO economist
indicators are within/close to the estimated range. Fig. 1 VH-1MDX microhardness tester with a 300 g load.
(a and b) present the estimates of the performance Investigation has shown that the uniformity of the
indicators for all 9 combinations ((((𝑞𝑖 𝑣𝑗 ℎ𝑘 ), 𝑘 = nanoparticle spreading in the weld piece rises with the
1,2,3), 𝑗 = 1,2,3), 𝑖 = 1,2,3) of SLM process parameters. augmentation of the quantity of FSP passes. Subsequently,
Using the additive law from the mean values of ANOVA to attain the finest possible nano particle allocation,
presented in Table 4, the predicted hardness for cylindrical different FSP passes are utilized [4]. The tool material
and square pin respectively as, picked was AISI M2 and its chemical composition is
HV = 174.64 + 0.341667ξ1 − 4.90ξ12 + given in Table 5. SEM analysis is also carried out.
0.081667ξ2 − 0.02ξ22 (4) Table 5: Chemical configuration of AISI M2 tool
2
HV = 267.622 + 10.32583ξ1 − 9.2695ξ1 + %C %Mn %Si %Cr %W %Mo %V %Ni
3.17583ξ2 − 3.1645ξ22 (5) 0.85 0.3 0.3 4.15 6.4 5.0 1.9 -
Where, 𝜉1 = (𝑆𝑝𝑒𝑒𝑑 − 1200)/500 and 𝜉2 = (𝐹𝑒𝑒𝑑 −
90)/40. The relative error (RE) is calculated as, 3. Results and discussion
Estimate
RE (%) = 100 × (1 − ) (6) During FSP, the heat generated by tool causes the
Test
temperature in the weld nugget to increase significantly,
The graphs in Fig. 1 contains the upper bound, lower reaching close to the solidus temperature of the material.
bound and the test data which clearly shows that the test This high temperature leads to the dissolution and
data was within the boundary region. reprecipitation of some intermetallic particles within the
Table 4: Estimates of performance responses weld nugget. To investigate the presence of these
intermetallic particles in the weld nugget, SEM was
Range
Test Eqn. (3) RE (%) Eqn. (2) utilized. In this case, EDS was employed alongside SEM
Upper Lower
to identify the elemental composition of the intermetallic
Cylindrical pin
particles. The result of SEM-EDS study revealed the
171.254 174.292 -1.77 171.254 171.254 176.369
presence of intermetallic particles in the weld nugget of
175.361 174.399 0.55 175.361 171.360 176.475
all the specimens, despite the inclusion of different types
176.532 174.456 1.18 176.532 171.417 176.532
of reinforcing nanoparticles. This finding suggests that
181.210 179.531 0.93 181.210 176.492 181.607
FSP process might have a consistent effect on the
179.226 180.645 -0.79 179.226 177.607 182.721
dissolution and reprecipitation of specific intermetallic
178.426 179.694 -0.71 178.426 176.656 181.770
particles, irrespective of the type of nanoparticles present.
176.335 175.984 0.20 176.335 172.945 178.060
To delve further into the examination of the intermetallic
174.531 175.082 -0.32 174.531 172.044 177.158
particles at a nanoscale level, TEM was employed. TEM
174.331 175.139 -0.46 174.331 172.101 177.215
is a technique that uses an electron beam transmitted
Square Pin
through a thin specimen to create detailed images and
242.215 241.686 0.22 242.215 235.281 247.562
246.568 248.026 -0.59 246.568 241.621 253.902
gather structural information at the atomic level. TEM
248.967 248.038 0.37 248.967 241.633 253.914
analysis would provide a more detailed understanding of
254.876 261.281 -2.51 254.876 254.876 267.157
the intermetallic particles, their size, distribution and any
271.532 271.194 0.12 271.532 264.789 277.070
potential changes in their crystalline structure induced by
270.128 267.633 0.92 270.128 261.228 273.509 FSP. In summary, the statement highlights the occurrence
268.214 265.910 0.86 268.214 259.505 271.786 of intermetallic particle dissolution and reprecipitation
266.226 268.678 -0.92 266.226 262.273 274.554 during FSP due to the elevated temperature in the weld
265.265 268.689 -1.29 265.265 262.284 274.565 nugget. The use of SEM with EDS allowed for the
identification of intermetallic particles, while TEM was
employed for a more detailed examination at the
nanoscale. The findings indicated that despite the
presence of various reinforcing nanoparticles, all
specimens exhibited the same intermetallic particles,
indicating a consistent effect of FSP on their behavior.
Fig. 2 shows the optical micrographs of the weld
nuggets of the optimum specimens, as well as the optical
micrograph of the base metal. The same magnification is
used for comparison purposes. Although the base metal is
Fig. 1: Experiments for hardness, Hv (a) for straight cylindrical pin characterized by relatively large and elongated grains in
and (b) for square pin the rolling direction, all the friction stir welded and
processed specimens present a weld nugget
After welding, the specimens were cut transversely to
microstructure characterized by small and equiaxed
the welding direction and the preparation for the
grains. An absence of agglomeration and a good material
metallographic observation took place, i.e., grinding,
mixing were observed. The study of FSP AA6082 using
polishing and etching with the Poulton’s reagent. The
TEM is underrepresented in international literature [23-
determination of the optimum specimen for each case
25]. Separation vortices, brought about by the rotation of
(tungsten reinforcement with cylindrical and square pin)
the tool pin, are presented in Fig. 3. No particular closures
took place using an optical stereoscope. The Vickers

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 Syed et al. 2023. Int. J. Vehicle Structures & Systems, 15(6), 802-807
of dislocation, allocation can be drawn as there is no
specific model monitored. Few partials are occupied at the
partitions while remaining show up as essentially
permitted of them. In Fig. 4, the absolute beginning stage
of the creation of a separation cell development can be
observed which goes about as a predecessor to sub grain
development through dynamic recovery and the following
extraordinary recrystallization.
Fig. 2: Optical micrographs of the weld nugget of the specimens - (a)
un-reinforced, (b) reinforced with W and cylindrical pin, (c)
reinforced with W and square pin, (d) 6082-T6 base metal
Fig. 3: TEM analysis - (a, b) particle boundaries and (c, d) cell
erection
Fig. 4: TEM analysis of (a) un-reinforced (b) cylindrical pin and (c)
square pin
As tungsten nanoparticles have exceptional size near
to the minimal (Fig. 5), roughly intermetallic particles
seem to leave a track of displacement. That have been
monitored exceptionally by virtue of the W-reinforced
sample, perhaps cause of the lesser feed stood out from
un-reinforced and reinforced specimens. As growth in
805
WN's microhardness was because of the decrease of the
particle size in the specimen. Likewise, the W
nanoparticles have distant shape (Fig. 6). AA6082-T6
base metal microhardness stayed at ~110 HV0.3. The W -
reinforced models presented similar microhardness
spreading different zones (Weld Nuggets (WN) and Heat
Affected Zone (HAZ)) (Fig. 7). The un-reinforced and the
tungsten-reinforced specimens presented similar
microhardness distribution in all zones (WN, HAZ) (Fig.
8). The tool profile impact on the base metal is varying
due to the shape of the pin/probe. FSP has emerged to
create surface composites and combine them with
aluminum matrix in the solid state. As FSP applied to
Al6082, microhardness was changed drastically (Fig. 9).
It is shown that by using square pin and straight
cylindrical tool, the microhardness is 48% and 30%
respectively increased when compared to AA6082
reinforced base metal.
Fig. 5: TEM analysis of the weld zone using square tool
Fig. 6: TEM analysis of the weld zone using cylindrical tool
Fig. 7: Microhardness for un-reinforced specimens
Fig. 8(a): Microhardness results for the W-reinforced specimens, at
1 and 2 passes with cylindrical probe tools
 Syed et al. 2023. Int. J. Vehicle Structures & Systems, 15(6), 802-807
Fig. 8(b): Microhardness results for the W-reinforced specimens, at
1 and 2 passes with square probe tools
Fig. 9: Microhardness values of different specimens
4. Conclusion
In this research involving FSP of AA6082-T6, the grains
are distinguished to nano levels and the boundaries are
visibly uncovered. The particles are dispersed uniformly
in aluminum matrix. Porosity was nearly removed.
Fabrication is done by combination of Tungsten nano
sized particulates in the cast aluminum matrix. Tungsten
dissemination in the stir zone is improved by multi-pass.
Square tool (‘U’ shaped groove) has increased the
microhardness in the weld zone and W particles properly
embedded into the base material. Straight cylindrical tool
has increased microhardness compared to the base
material and greater number of weld nuggets is observed
in the weld zone.
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