FRICTION STIR CASTING OF AL-COPPER ALLOY FOR WELD IMPROVEMENT IN AERO APPLICATIONS

Abstract

This study investigates the design and transient thermal analysis of TIG welded plates using a stir casting process, specifically focusing on Aluminum 6061 reinforced with Silicon Carbide (SiC) and Copper reinforced with Boron Carbide (B4C). The primary aim is to explore the effect of varying reinforcement percentages and processing conditions on the weld zone’s thermal behavior. Reinforcement materials were incorporated at varying concentrations of 6%, 8%, and 10% for SiC in aluminum, and 4%, 6%, and 8% for B4C in copper. Different processing temperatures and stir speeds were employed to determine optimal parameters. The experimental design follows the L9 orthogonal array from Taguchi's Design of Experiments (DOE), enabling systematic variation of the process parameters for optimal performance. Thermal analysis was conducted using the ANSYS software, employing the transient thermal module to evaluate the temperature distribution, heat flow, and thermal errors within the weld zone. Structural analysis was also performed to assess the total deformation and maximum stress under thermal conditions, ultimately offering insights into the effects of reinforcement and processing variables on the welded material's mechanical properties