6127-THE KAVERY ENGINEERING COLLEGE

MECHANICAL ENGINEERING
B5-FINAL YEAR PROJECT

BATCH MEMBERS
612718114301 – LOKESH.M
612718114303 – MATHESH.M GUIDE BY
612718114305 – NANDHAGOPAL.S Mr. SATHEESH KUMAR
612718114309 – SATHYAPRAKASH.S (AP/MECH/TKEC)
AIM :

Effect of processing parameters on the microstructure

and tensile properties of a copper metal matrix
composite during friction stir processing
OBJECTIVES :

• To identify the materials

• To fabricate composites
• To make weld on composites materials
• To evaluate effect of process on microstructure and tensile
properties of magnesium and copper
INTRODUCTION

• Friction stir welding (FSW) is a solid state joining process

that invented at the welding institute (TWI) united kingdom
in 1991,is available technique for joining aluminium alloys
that are difficult to fusion welding.
• Aluminium to copper dissimilar joints is often used in variety
of applications,electrical connectors,condenser and
capacitor foil windings,refrigeration tubes.
FRICTION STIR WELDING:
• FSW works by using a non-
consumable tool, which is rotated
and plunged into the interface of
two workpices.
• The tool is then moved through the
interface and the frictional heat
causes the material to heat and
soften.
LITERATURE REVIEW
• As per Mishra and Ma (2005) in FSW a revolving toolwith a
specifically designed pin is placed into sides ofplates to be
joined. The tool then moves alongside thejoint line, and plates
are welded. According to Khaled(2005) when fastened joints are
replaced with FSWjoints, the result is weight and cost savings.
Weightand cost savings are essential for aerospace industry.
• Weight savings are achieved due to the elimination ofthe
fasteners. Cost savings are achieved because of adecrease in
design, manufacturing, assembly, andmaintenance time.
• Erim and Cam (2014) welded AA6061plates in O and T6-
temper state FSW in but position. After post-weld heat
treatment, mechanical properties of FSW joints significantly
improved with respect to as-welded plates and respective base
plates.
• Ca metal 2014 concluded that chemistry of dynamically
recrystallized zone (DXZ) of AA6061-T6 joints
• The service qualities of the welded Al-alloy joints in the
aerospace industry can be improved using FSW,which was
initially used for welding difficult-to-weld high strength Al-
alloys (Cam, Ipekoglu, & Tarık Serinx0002dag, 2014 Bhushan
& Sharma, 2019).
MECHANICAL PROPERTIES OF COPPER
PROPERTIES COPPER
Density 9.40g/cm3
Tensile strength 170MPa
Thermal conductivity 52W/mk
Hardness 50
Melting Temp 1085℃
MECHANICAL PROPERTIES OF MAGNESIUM

PROPERTIES MAGNESIUM

Melting point 650℃

Thermal conductivity 156 W m-1 k-1

Density 1.738 (g/cm3)

Specific Heat 1.017

(a) Copper Rod (b) boroncarbides & Tungsten (c) Magnesium
CASTING PROCESS:

• When a pure copper rod is

melted at 1065 degree celsius
and adding a tungsten powder
and boran carbide powder and
mixed well my the
mixer(stirrer).
• It will be pouring in a pattern of
rectangular plate die. copper alloy
plate is make by casting process.
• Plate size = 100*100*6mm
Casting process
FRICTION STIR WELDING
WELDING PARAMETERS:
PARAMETERS WORKPIECE -I WORKPIECE-II WORKPIECE-III

Rotational speed1 1200rpm 900rpm 1500rpm

Feed 12mm/min 9mm/min 15mm/min

Axial force 6KN 3KN 9KN

Depth 5.7mm 5.7mm 5.7mm

 PROPOSED WORK :
Find the properties