CHENNAI INSTITUTE OF TECHNOLOGY Sarathy Nagar, Kundrathur, Chennai-600069 An Autonomous Institute Approved by AICTE and Affiliated to Anna University, Chennai MECHANICAL ENGINEERING Tensile properties investigation of AZ91 magnesium alloy welded using friction stir welding under varied parameters. « CHENNAI INSTITUTE oe TECHNOLOGY A Report on Core Course Project By: P.A.RYAN AHMED & MOHAMMED ARSHAD REG NO: 23ME064, 23ME0SS OCTOBER 2024 CHENNAI INSTITUTE OF TECHNOLOGY CHENNAI-69 1[PageCHENNAI @ ge CHENNAI INSTITUTE @F! tecHnotocy INSTITUTE OF TECHNOLOGY = ome Vision of the Institute: To be an eminent centre for Academia, Industry and Research by imparting knowledge, relevant practices and inculcating human values to address global challenges through novelty and sustainability. Mission of the Institute: IM1.To creates next generation leaders by effective teaching learning methodologiesand instill scientific spark in them to meet the global challenges. IM2.To transform lives through deployment of emerging technology, novelty andsustainability. IIM3.To inculcate human values and ethical principles to cater the societal needs. IM4.To contributes towards the research ecosystem by providing a suitable, effectiveplatform for interaction between industry, academia and R&D 2|PageDEPARTMENT OF MECHANICAL ENGINEERING Vision of the Department: To Excel in the emerging areas of Mechanical Engineering by imparting knowledge, relevant practices and inculeating human values to transform the students as potential resources to cater the needs of the industries and society in order to uphold the sustained ‘manufacturing activities 1n of the Department: DMI: To provide strong fundamentals and technical skills in Mechanical Engineering through effective teaching leaning Methodologies. DM2: To transform lives of the students by fostering ethical values, creativity and innovation to become Entrepreneurs and establish Start-ups. DM3: To habituate the students to focus on sustainable resources with optimal usage to ensure the welfare of the society. DM4: To provide an ambience for research through collaborations with industry and academia. DMS: To inculcate learning of emerging technologies for pursuing higher studies leading to lifelong leaming. 3|PageCHENNAI INSTITUTE OF TECHNOLOGY An Autonomous Institute CHENNAI-69 CHENNAI INSTITUTE oe TECHNOLOGY nae CERTIFICATE This is to certify that the “Core Course Project” Submitted by P.A.Ryan ahmed (Regno: 23ME064) and Mohammed Arshad (Reg no:23MEO11) is work done by them and submitted during 2024-2025 academic year, in partial fulfilment of the requirements for the award of the degree of BACHELOR OF ENGINEERING in DEPARTMENT OF MECHANICAL ENGINEERING, at Core Course Project on Tensile properties investigation of AZ91 magnesium alloy welded using friction stir welding under varied parameters, Core Course Project Coordinator Internal Examiner Head of the Department External Examiner 4|PageACKNOWLEDGEMENT We express our gratitude to our Chairman Shri. P. SRIRAM and all trust members of Chennai institute of technology for providing the facility and opportunity to do this project as a part of our undergraduate course. We are grateful to our Principal Dr. A. RAMESH M.E, Ph.D. for providing us the facility and encouragement during the course of our work. We sincerely thank our Head_-—sof_~—the_-—-‘Department, Dr.P.Gurusamy M.E, Ph.D Department of Mechanical Engineering for having provided us valuable guidance, resources and timely suggestions throughout our work. We would like to extend our thanks to our Faculty coordinator of the Department of Mechanical Engineering Mr. Sasi Lakshmikhanth R, for his valuable suggestions throughout this project. We wish to extend our sincere thanks to all Faculty members of the Department of Mechanical Engineering for their valuable suggestions and their kind cooperation for the successful completion of our project. We wish to acknowledge the help received from the Lab Instructors of the Department of Mechanical Engineering and others for providing valuable suggestions and for the successful completion of the project. P.A.RYAN AHMED 23ME064 MOHAMMED ARSHAD 23ME0SS s|PagePREFACE ‘We students of Mechanical engineering department are require to do An Project to enhance my knowledge. The purpose of core course Project is to acquaint the students with practical application of theoretical concept taught to us during my course period. It was a great opportunity to have close comparison of theoretical concept in practical field. This report may depict deficiencies on our part but still it is an account of our effort. The output of our analysis is summarised in a shape of Industrial Project the content of report shows the details of sequence of these. This is my Core Course Project report which I have prepared for the sake of my second year Project. Being an engincer, I should help the society for inventing something new by utilising my knowledge which can help them to solve their problem. 6|PageABSTRACT The project investigates the tensile properties of AZ91 magnesium alloy welded using Friction Stir Welding (FSW) under varied parameters. This work is significant as AZ91 alloy, with its low density and excellent ‘mechanical properties, is commonly used in the automotive and aerospace industries. However, optimizing its ‘weld quality remains challenging due to issues like brittleness and grain coarsening at high temperatures. The problem addressed in this study is improving the tensile strength of AZ91 alloy welds by adjusting FSW parameters, such as tool rotation speed, welding speed, and axial force. ‘The methodology includes a systematic exploration of different FSW parameter sets, performing tensile tests on welded specimens, and analyzing fracture patterns. The investigation emphasizes identifying the relationship between FSW settings and weld microstructure that influences tensile properties. ‘The results are expected to show that fine-tuning FSW parameters can significantly enhance the tensile strength and ductility of AZ91 alloy welds. This project contributes to the broader field of welding metallurgy by offering insights into optimal welding conditions for magnesium alloys, which could help expand their application in weight-critical engineering components, 7|PageCONTENT S.NO TITTLE PG.NO 1. INTRODUCTION 9 TW Magnesium Alloys rr) T2___| Applications of magnesium alloys: 10 T3__ | Types of Welding process: TI T4__ | Significance of FSW: TI 13 ___| Process Parameters: 2 1.6 __ | Design of experiment by RMS and ANOVA: z LITERATURE SURVEY 3 21 Literature review 3 22 ___ |Research gap 15 23__| Problem statement 16 24__ | Problem objective 16 3 RESULTS AND DISCUSSION 7 3.1 ___ | Development and Validation of empirical relationship 7 32__| Eifect of input parameters on the tensile strength 19 4 ‘CONCLUSION 5a) 3 REFERENCE, 22 [Page1. INTRODUCTION 1.1 Magnesium Alloys Magnesium alloys, known for their light weight and excellent strength-to-weight ratio, are widely used in industries such as automotive, aerospace, electronics, and biomedical applications. Magnesium, being the lightest structural metal, is alloyed with elements such as Magnesium, zinc, manganese, and rare earth metals to improve its mechanical properties, corrosion resistance, and overall performance. The demand for magnesium alloys is steadily increasing due to the growing emphasis on fuel efficiency and weight reduction, especially in the transportation sector. Magnesium alloys are typically classified into two main categories: cast and wrought alloys. Cast ‘magnesium alloys are formed by pouring molten metal into molds, allowing for complex shapes, making them popular in automotive components like gearboxes and steering wheels. Wrought magnesium alloys, on the other hand, ate produced by mechanical processes such as rolling, extrusion, and forging, and are used in applications requiring higher strength and toughness, such as aerospace components and structural parts One of the most widely used magnesium alloys is AZ91, an alloy of magnesium with Magnesium and zine. AZ91 offers a good balance of mechanical properties, corrosion resistance, and castability, making it ideal for automotive and aerospace parts. The presence of Magnesium provides strength and castability, while zine improves corrosion resistance. However, AZ91 has limited high-temperature performance, which restricts its use in applications that involve prolonged exposure to elevated temperatures. In recent yeats, there has been significant research aimed at improving the mechanical properties and corrosion resistance of magnesium alloys. Alloying magnesium with rare earth elements, such as neodymium and yttrium, has been shown to enhance both its strength and resistance to creep at high temperatures, making these alloys suitable for high-performance applications in aerospace and defense sectors. These rare earth magnesium alloys have superior properties, including excellent tensile strength, fatigue resistance, and thermal stability Despite their desirable properties, magnesium alloys have certain limitations, such as poor corrosion resistance in chloride-rich environments and difficulty in welding. Magnesium’s high reactivity can lead to rapid oxidation, especially during welding, making it prone to defects like porosity and cracking. Advanced welding techniques, such as Friction Stir Welding (FSW), are being explored to mitigate the issues and expand the applications of magnesium alloys in various industries 1.2 Applications of magnesium alloys Magnesium alloys are increasingly utilized across a wide range of industries due to their unique combination of lightweight properties and high strength-to-weight ratio, In the automotive sector, these alloys play a crucial role in manufacturing components such as engine blocks, gearboxes, and wheels. ‘Their lightweight nature contributes significantly to enhanced fuel efficiency and overall vehicle performance, enabling manufacturers to produce lighter vehicles that consume less fuel and emit fewer greenhouse gases, In the aerospace industry, magnesium alloys are employed in the construction of aircraft structures, including frames, landing gear, and fuselage components, The low density of ‘magnesium helps reduce the overall weight of aircraft, which is critical for improving fuel efficiency and increasing payload capacity. This makes magnesium alloys a favored choice in the design of advanced aerospace systems, where performance and fuel economy are paramount. In the electronics industry, 10|Pamagnesium alloys are used to produce lightweight housings and components for devices such as laptops, smartphones, and tablets. The strength of magnesium alloys provides excellent protection for sensitive electronic components while maintaining a minimal weight, which is essential for portable electronics. Additionally, the aesthetic appeal of magnesium allows for sleek designs in consumer clectronics, 1.3 Types of Welding process Magnesium alloys can be welded using a variety of techniques, each chosen based on the specific alloy, material thickness, and desired joint properties. Some of the most common welding methods for Magnesium alloys include: 1, Gas Tungsten Arc Welding (GTAW or TIG): Tungsten Inert Gas (TIG) welding is widely used for magnesium due to its ability to provide high-quality, precise welds. It employs a non-consumable tungsten electrode and is particularly effective for thin Magnesium sheets, The process produces a clean, aesthetically pleasing weld, though it can be slower and requires skilled operators. 2. Gas Metal Are Welding (GMAW or MIG): Metal Inert Gas (MIG) welding is a faster and more automated method than TIG, making it suitable for thicker magnesium alloys. In this process, a consumable wire electrode is fed continuously while an inert gas, typically argon or helium, shields the weld from oxidation. MIG welding is widely used in industries like automotive and shipbuilding where productivity is key. 3. Friction Stir Welding (FSW): FSW is a solid-state welding process that is particularly effective for magnesium alloys. It involves rotating a non-consumable tool that generates heat through friction, softening the metal without melting it. This method creates a high-strength weld with minimal distortion, making it ideal for aerospace, automotive, and shipbuilding applications, 4, Laser Beam Welding (LBW): Laser beam welding is favored for its precision and ability to create deep, narrow welds in magnesium, It uses @ concentrated beam of light to fuse metals with high energy density, making it suitable for applications requiring minimal heat input, such as thin magnesium parts or delicate structures. 5. Electron Beam Welding (EBW): EBW is a high-energy process that uses a focused beam of electrons to weld magnesium alloys in a vacuum environment. This method provides deep penetration and precise control, making it suitable for critical aerospace applications where joint integrity is crucial. 6. Cold Metal Transfer (CMT): CMTis an advanced version of MIG welding that is optimized for welding thin magnesium materials. It uses a lower heat input, reducing the risk of defects such as porosity and cracking, which are common in high-strength Magnesium alloys like 7075. CMT is used in applications requiring high-quality welds with minimal distortion. 7. Resistance Welding: This process, including spot and seam welding, is used for joining Magnesium sheets by applying pressure and passing an electrical current through the material. Resistance welding is fast and used extensively in industries like automotive, where high-speed production is critical 10|PaEach welding method has its strengths and limitations, and the choice depends on factors like the alloy composition, thickness, joint design, and the mechanical properties required for the final product, 1.4 Significance of FSW Friction Stir Welding (FSW) is an innovative welding technique that has transformed the way materials, particularly lightweight alloys like Magnesium and magnesium, are joined. This solid-state process offers significant advantages over traditional welding methods, making it a preferred choice in various industries, including aerospace, automotive, and marine. The significance of FSW lies primarily in its ability to produce high-quality welds without melting the base materials, thus preserving their original mechanical properties. One of the key benefits of FSW is its low heat input, which minimizes thermal distortion and residual stresses often associated with conventional welding processes, This characteristic is crucial in applications where structural integrity is paramount, such as in aireraft frames and automotive body components. Additionally, FSW reduces common welding defects like porosity and cracking, resulting in stronger and more reliable joints. ‘The versatility of FSW extends to its ability to join dissimilar materials, enabling the production of lightweight hybrid structures that combine the best properties of different metals. This capability is particularly important as industries move towards designing more efficient and sustainable products. Moreover, FSW generates minimal spatter and fumes, leading to a cleaner working environment and, reducing the need for extensive post-weld treatments. Its application has facilitated advancements in ‘manufacturing processes, contributing to the development of high-performance materials and components essential for modern engineering challenges. Overall, FSW represents a significant advancement in welding technology, driving innovation and efficiency in the production of critical structures across various sectors Applied Force Friction 11|Page1.5 Process Parameters Friction Stir Welding (FSW) is a solid-state welding process that relies on specific parameters to achieve optimal weld quality and performance. The main process parameters include tool rotation speed, welding, speed, axial force, and tool design, cach of which plays a crucial role in the overall outcome of the welding operation, Tool Rotation Speed: This parameter controls the amount of heat generated through friction between the rotating tool and the workpieces. A higher rotation speed can produce more heat, facilitating better ‘material flow, but it may also lead to overheating and a decrease in mechanical properties. Conversely, a lower rotation speed may not generate sufficient heat for effective welding. ‘Welding Speed: The speed at which the tool traverses along the joint line is also critical. An optimal ‘welding speed ensures proper heat distribution and material mixing. Too fast a speed may result in inadequate heat input, leading to weak welds, while too slow a speed can cause excessive heat buildup, resulting in defects. Axial Force: The force applied along the tool’s axis is essential for maintaining contact between the tool and the workpieces. Insufficient axial force can lead to improper material deformation, while excessive force may cause tool wear and damage to the welded materials Tool Design: The geometry of the FSW tool, including its pin shape and shoulder diameter, significantly influences weld quality. A well-designed tool promotes effective material flow and minimizes defects. ‘Various designs, such as tapered pins or threaded pins, can be used depending on the specific application and materials being welded. In conclusion, carefully optimizing these process parameters is essential for achieving high-quality welds in FSW. A systematic approach to adjusting these factors can enhance the mechanical properties and overall integrity of the welded joints, making FSW a powerful technique in modern manufacturing, 12|Page1.6 Design of experiment by RMS and ANOVA In this research, Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) are employed to optimize the welding parameters for magnesium alloy welded using friction stir welding under varied parameters. Friction Stir Welding (FSW) has emerged as a highly effective method for joining lightweight materials such as ‘magnesium alloys, which are increasingly used in automotive and aerospace applications. The AZ91 magn alloy, known for its excellent mechanical properties and corrosion resistance, presents unique challenges in welding due to its susceptibility to defects. To optimize the FSW process parameters for AZ91, a systematic approach using Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) is employed. ‘The primary goal of this experimental design is to evaluate the effects of various welding parameters—tool rotation speed, welding speed, and axial force—on the quality of the welds produced in AZ91 magnesium alloy. ‘The responses of interest include tensile strength, hardness, and defect rate ‘The experimental framework begins with the selection of key process parameters, Three main factors are identified for this study: 1. Tool Rotation Speed (RPM): This influences heat generation and material flow during welding 2, Welding Speed (mm/min): This affects the heat input and mixing time 3. Axial Force (KN): This parameter impacts the contact pressure at the weld interface. varied at A Central Composite Design (CCD) is chosen to explore the parameter space efficiently. Each factor three levels (low, medium, and high), allowing for the investigation of both linear and interaction effects among the variables, Experiments are conducted according to the CCD matrix, and measurements are taken for tensile strength, hardness, and defect rate for each welding trial. The collected data is then analyzed using RSM to develop a second-order polynomial regression model. This model establishes relationships between the process parameters and the response variables, facilitating the visualization of response surfaces. Once the regression model is formulated, ANOVA is utilized to assess the significance of each factor and their interactions on the response variables. The ANOVA table provides p-values that indicate whether the parameters significantly influence the weld quality. Typically, a p-value of less than 0.05 suggests a significant effect, allowing for the identification of critical parameters. ‘The results from ANOVA guide the optimization of the FSW process. The RSM model can be used to predict the optimal combinations of parameters that maximize tensile strength and minimize defects. After identifying these optimal settings, validation runs are conducted to confirm the model’s predictions and ensure reproducibility of results, ‘The combined approach of RSM and ANOVA offers a robust methodology for optimizing the Friction Stir Welding process of AZ91 magnesium alloy. This structured approach not only enhances the understanding of the relationships between welding parameters and weld quality but also enables the development of efficient welding processes that mect stringent industry standards. By systematically analyzing and optimizing these factors, ‘manufacturers can produce high-quality, defect-free welds, thereby enhancing the performance and reliability of components made from AZ91 magnesium alloy quality 1B|Page2. LITERATURE SURVEY 2.1 Literature Review FSW has been primarily applied for the joining of nonferrous materials such as Magnesium and to a lesser extent for magnesium alloys. Nonferrous materials such as Magnesium and magnesium have many attractive properties in structural field, Magnesium and its alloy are grouped under rare earth metal category, and these metals have been used for structural application because of its strength to weight ratio (more compared to other metal). Magnesium is the third-most-commonly-used structural metal, followed by iron and Magnesium. Ther ‘magnesium alloys ‘used for different applications, AZ 91 one of the magnesium alloys, which was used for investigating the effect of FSW parameters on tensile strength. S, Ramesh Babu et al. investigated the microstructural and mechanical properties of extruded AZ31B during FSW and found that good welding and defect free stir zone is obtained with {o0I rotation speed of 1000 rpm with shoulder diameter as 24 mm, tool traversing speeds of 75 and 105 wre many Building on this foundation, the paper "An Investigation into Friction Stir Welding of magnesium Alloy 5083-H116 Similar Joints" further highlights the significance of FSW, particularly for magnesium alloys used in marine, transportation, and military applications. Magnesium alloy AAS083-H116 benefits from FSW due to its strain-hardened properties and superior corrosion resistance. Studies such as those by Minton and Jamshidi have illustrated that controlling heat input and welding speed are crucial for maintaining mechanical properties like strength and grain size, The role of dynamic recrystallization in enhancing joint strength is emphasized, while numerical models have been employed to predict thermal cycles, confirming, the importance of heatmanagement in optimizing weld outcomes, ‘The review continues with the study "Microstructure, Mechanical and Corrosion Behavior of High Strength AZ91 Magnesium Alloy Friction Stir Welds - Effect of Post Weld Heat Treatment," which focuses on the challenges associated with welding high-strength magnesium alloys alloys like AZ91D This alloy is extensively used in acrospaceand defense industries but suffers from poor weldability and corrosion resistance when using fusion welding techniques. FSW provides a solution, but the process introduces microstructural changes in the weld, heat-affected zones (HAZ), and thermo- mechanically affected zones (TMAZ), which can degrade hardness and corrosion resistance. Post-weld heat treatments such as peak aging (T6) and retrogression and re- aging (RRA) have been explored to improve these properties, with RRA offering a better balance between strength and corrosion resistance. This further highlights the need for precise control of FSW parameters and post-weld treatments to optimize both mechanical properties and long-term durability of joints, Tungsten Inert Gas (TIG) welding is preferred for its ability to produce high-quality welds with fewer defects. Previous studies on alloys like WE43, HK31, and ZC63 have demonstrated the benefits of optimizing welding parameters like peak current, base 14|Pagecurrent, and welding speed using methods such as the Taguchi design to improve tensile strength, hardness, and impact resistance. However, limited research has specifically examined ZC71, leaving a gap that this study aims to fill by exploring its weldability through TIG welding and optimizing process parameters to enhance mechanical propetties. Furthering this discussion, research on the effect of varying rotational speed, plunge depth, and welding speed on the ultimate tensile strength (UTS) during the friction stir welding (FSW) process of Magnesium alloy AZ91 highlights the advancements in FSW, a solid-state welding technique. Widely used in aerospace, shipbuilding, and automotive industries, AZ31 is preferred due to its high strength-to-weight ratio and excellent machinability. FSW offers the advantage of creating high-strength joints with minimal defects. Previous studies have demonstrated that the UTS is highly dependent on welding parameters such as rotational speed, plunge depth, and welding. speed. Adjusting these parameters affects heat generation, material deformation, and grain structure, ultimately influencing the strength and quality of the weld, FSW is also environmentally friendly, requiring less energy and producing fewer emissions than traditional welding methods, Additionally, a comparison of magnesium welds produced by Laser Beam Welding (LBW), Friction Stir Welding (FSW), and riveting for aeronautical structures reveals that while riveting has traditionally been the preferred method, LBW and FSW offer significant advantages. LBW provides precision and minimal heat-affected zones, reducing distortion, while FSW offers superior fatigue resistance and lower residual stress. Studies show that LBW performs better in T-pull tensile tests, while FSW excels in Hoop tests, making both viable replacements for riveting. However, riveting has lower mechanical strength due to stress concentrators around rivet holes, which initiate cracks. The adoption of LBW and FSW in aeronautical applications is growing, as they reduce weight and improve the overall performance of aircraft The comparative study of laser beam welding (LBW) and clectron beam welding (EBW) for Magnesium alloy focuses on the microstructural and mechanical differences between the two processes, EBW results in superior joint quality due to its vacuum environment, which eliminates weld seam pores and reduces hydrogen-related defects. ‘The EBW joints exhibit smaller grain sizes and a higher depth-to-width ratio, leading to improved mechanical properties such as tensile strength and hardness compared to LBW. Despite LBW producing a wider weld seam, EBW offers higher tensile strength and ductility, making it a more effective welding method for Magnesium alloys in industrial applications. Similarly, in the case of pulsed laser welding of AZ31B magnesium alloys using a copper (Cu) interlayer, the study addresses the challenges of 15|Pagedissimilar metal welding due to the formation of brittle intermetallic compounds (IMCs) such as Mg-Al compounds. The introduction of a Cu interlayer enhances joint quality by minimizing the formation of these compounds, particularly Mg17AI12 while introducing CuMg4, which improves joint strength and plasticity. The study identifies optimal welding parameters, including laser power, pulse width,and speed, to ensure high-quality welds with minimal defects. Furthermore, the Cu interlayer enhances the corrosion resistance of the joints, with corrosion resistance decreasing in the order of the weld beam, AZ31B Mg. 2.2 Research Gap AZ91 magnesium alloy is renowned for its exceptional lightweight properties, high strength-to- ‘weight ratio, and excellent corrosion resistance, making it a prime candidate for applications in aerospace, automotive, and other demanding industries. However, the effective welding of AZ91 alloy presents significant challenges due to its unique metallurgical properties, particularly when utilizing Friction Stir Welding (FSW). While FSW has demonstrated superior performan joining magnesium alloys, a thorough investigation into the tensile properties of AZ91 welded ‘under various parameters remains underexplored. This research gap necessitates a comprehensive understanding of how different welding conditions impact the mechanical properties and overall performance of the welded joints. Existing research on FSW of AZ91 magnesium alloy has primarily focused on establishing the feasibility of the process, often neglecting systematic studies on the optimization of welding parameters such as tool rotation speed, welding speed, and axial force. While some studies have highlighted the importance of these parameters in achieving high-quality welds, there is a lack of detailed investigations correlating specific parameter combinations with tensile properties. The need for comprehensive studies that explore the interplay of these factors is critical, as the optimization of FSW parameters directly influences the mechanical integrity and performance of the welded joints ‘The Heat-Affected Zone (HAZ) plays a crucial role in determining the mechanical properties of welded joints, particularly in magnesium alloys like AZ91. However, there is limited research focusing on the microstructural changes that occur within the HAZ during FSW. Understanding the relationship between microstructural alterations and tensile properties is essential for predicting the performance of welded joints under service conditions. Existing studies often provide qualitative insights but lack quantitative assessments of how different welding parameters affect the HAZ and, consequently, the tensile strength of the joint. This gap indicates the necessity for in-depth microstructural analyses coupled with tensile testing to establish a comprehensive understanding of the effects of FSW parameters. While there are studies that evaluate the tensile strength of AZ91 welded using FSW, there is a notable absence of comprehensive assessments that include other mechanical properties such as, ductility, hardness, and fatigue resistance. Investigating these properties alongside tensile strength is essential for providing a holistic view of the performance of welded joints, Additionally, there is a need for comparative studies that assess the tensile properties of FSW those produced by conventional welding techniques, thereby highlighting the ind limitations of FSW for AZ91 magnesium alloy. Another significant research gap exists in the exploration of dissimilar welding using FSW, particularly involving AZ91 magnesium alloy. As industries increasingly look for lightweight 16|Pagehybrid structures that combine different materials, understanding how AZ91 can be effectively ‘welded to other alloys or materials becomes critical. Current literature lacks sufficient studies investigating the tensile properties of dissimilar joints formed using FSW. Such investigations are crucial for expanding the applicability of AZ91 in multi-material designs, which are common in modem engineering applications. There is a growing concem regarding the environmental impact of welding processes, particularly in terms of energy consumption and waste generation. However, studies focusing on the environmental implications of FSW for AZ91 magnesium alloy are scarce. Research should aim to assess the energy efficiency of FSW compared to traditional welding methods while simultaneously evaluating the mechanical properties of the resulting joints. Understanding the sustainability aspects of FSW, alongside its mechanical performance, could provide a compelling case for its adoption in various industries. To address the identified rescarch gaps, future studies should adopt a multifaceted approach that includes systematic parameter optimization, comprehensive mechanical property evaluation, ‘microstructural analysis, and environmental impact assessments. Conducting comprehensive experiments to explore the impact of tool rotation speed, welding speed, and axial force on the tensile properties of AZ91 welded joints while employing statistical analysis methods like RSM and ANOVA will yield valuable insights. Integrating microstructural characterization techniques such as scanning electron microscopy (SEM) and X-ray diffraction (XRD) will correlate microstructural changes within the HAZ with tensile properties. Furthermore, extending assessments beyond tensile strength to include ductility, hardness, and fatigue resistance of FSW joints will provide a holistic view of performance. Investigating the tensile properties of dissimilar joints formed with AZ91 and other materials will enhance the understanding of its applicability in lightweight hybrid applications. Lastly, evaluating the energy efficiency and environmental implications of FSW for AZ91 magnesium alloy will contribute to the sustainability discourse in welding technologies. The investigation of tensile properties of AZ91 magnesium alloy welded using FSW under varied parameters presents a significant research opportunity. Addressing the identified gaps will not only enhance the understanding of the mechanical behavior of welded joints but also contribute to the development of optimized welding practices that can meet the evolving demands of modern engineering applications. By exploring these aspects, researchers can pave the way for more effective utilization of AZ91 magnesium alloy in high-performance applications. 2.3 Problem Statement ‘The AZ91 magnesium alloy is widely recognized for its advantageous properties, including lightweight characteristics, high strength-to-weight ratio, and excellent corrosion resistance, ‘making it a crucial material in applications such as aerospace, automotive, and marine industries. Despite its beneficial attributes, the effective welding of AZ91 remains a significant challenge. Friction Stir Welding (FSW), a solid-state welding technique, offers potential advantages for joining this alloy, but optimizing the welding parameters is critical to achieving desirable tensile properties in the resulting joints One of the main challenges in welding AZ91 magnesium alloy is its susceptibility to defect including hot cracking, porosity, and compromised mechanical properties, particularly in the heat-affected zone (HAZ). Existing research primarily focuses on the feasibility of FSW for AZ91, often neglecting comprehensive investigations into how various welding parameters— such as tool rotation speed, welding speed, and axial force—impact tensile properties. This gap 17|Pagein knowledge limits the understanding of the optimal conditions necessary to produce high- strength welds that can withstand operational demands, Moreover, the HAZ, plays a vital role in determining the overall performance of welded joints. The thermal and mechanical effects during FSW can lead to significant microstructural changes in the HAZ, yet there is limited research quantifying these changes and correlating them with tensile properties. Understanding the relationship between microstructural evolution and tensile performance is essential for predicting the overall behavior of welded joints, Additionally, the potential for dissimilar welding involving AZ91 is underexplored. As industries, increasingly seek to develop hybrid structures that combine various materials, understanding the feasibility and performance of FSW joints formed with AZ91 and other alloys becomes critical Current literature does not sufficiently address the tensile properties of such dissimilar joints, leading to a gap in knowledge that could hinder innovation in multi-material design, Finally, with growing concems about the environmental impacts of manufacturing processes, it is essential to assess the sustainability of welding techniques like FSW, particularly concerning AZ91. While FSW is generally viewed as more environmentally friendly than traditional welding methods due to its lower heat input and energy consumption, specific studies investigating its energy efficiency and waste generation for AZ91 magnesium alloy are lacking. In summary, this research aims to investigate the tensile properties of AZ91 magnesium alloy ‘welded using FSW under varied parameters to address significant knowledge gaps in the field By systematically examining the impact of welding parameters on mechanical properties, exploring the effects of microstructural changes in the HAZ, investigating dissimilar welding possibilities, and evaluating the environmental implications of FSW for AZ91, this study seeks to contribute to the development of advanced welding practices. Ultimately, the findings will enhance the understanding of AZ91's weldability, thereby improving its applicability in high- performance engineering applications. 2.4 Problem Objective The primary objective of this research is to systematically investigate the tensile properties of AZ91 magnesium alloy welded using Friction Stir Welding (FSW) under varied welding parameters. By focusing on this specific alloy, the study aims to contribute valuable insights that can enhance the understanding of its weldability and mechanical performance, ultimately promoting its application in critical industries such as aerospace and automotive. The first goal is to identify and optimize key welding parameters, including tool rotation speed, welding speed, and axial force, to enhance the tensile strength and overall mechanical proper of the welded joints. By conducting a series of experiments that vary these parameters, the research aims to determine the optimal conditions that yield the best tensile performance in the AZ91 welded joints. Another critical aspect of the research is to analyze the microstructural changes occurring in the hheat-affected zone (HAZ) during FSW. This involves characterizing the microstructure through techniques such as scanning electron microscopy (SEM) and optical microscopy to identify grain size, phase distribution, and other relevant features. Understanding how these microstructural changes correlate with tensile properties will provide essential insights into the behavior of the ‘welded joints. Additionally, the study aims to conduct a comprehensive evaluation of the mechanical properties of the welded joints beyond tensile strength alone. This includes assessing ductility, hardness, and fatigue resistance. By evaluating multiple mechanical properties, the research seeks to provide a holistic understanding of the performance of the welded AZ91 joints, which is crucial for applications subjected to dynamic loads. 18|Page‘The investigation will also explore the potential for dissimilar welding involving AZ91 ‘magnesium alloy. This involves examining the tensile properties of joints formed between AZ91 and other materials or alloys, thereby expanding the understanding of hybrid structures. By assessing the performance of dissimilar joints, the rescarch aims to highlight the versatility of, FSW and its potential for innovative applications. Finally, the research will evaluate the environmental implications of the FSW process for AZ91 ‘magnesium alloy. This includes analyzing energy consumption and waste generation associated with the welding process. By understanding the sustainability aspects of FSW, the study aims to contribute to the development of more environmentally friendly manufacturing practices. 3,.RESULTS AND DISCUSSION 3.1 DEVELOPMENT AND VALIDATION OF EMPERICAL RELATIONSHIP In the investigation of the tensile properties of AZ91 magnesium alloy welded using Friction Stir Welding (FSW), developing and vatidating an empirical relationship is crucial for understanding how various welding parameters affect the mechanical performance of the welded joints. This process involves creating a mathematical model that correlates the input parameters—such as tool rotation speed, welding speed, axial force, and other relevant factors—with the resultant tensile properties, including tensile strength, ductility, and hardness. ‘The development of the empirical relationship begins with the design of experiments (DOE), utilizing techniques such as Response Surface Methodology (RSM). This approach allows for a systematic variation of the welding parameters to collect a comprehensive dataset that reflects their combined effects on tensile properties. The selection of parameters to be studied should be informed by preliminary investigations and existing literature to ensure that they encompass the critical factors affecting weld quality. Typical parameters may include tool rotation speed (RPM), welding speed (mm/min), axial force (N), and tool geometry Once the experimental data is gathered, statistical analysis is performed to identify trends and relationships between the parameters and the tensile properties. Various regression techniques, such as multiple linear regression or nonlinear regression, can be employed to fit the data to a ‘mathematical model. The empirical relationship can often be represented as a polynomial equation: Equation 1 TS = f(P1, P2, P3) = KiP.-KaP2+:PstK PsP2t KP Pst KaP2Ps Where TS is the tensile strength,P,.P2,Ps represent the different welding parameters and Kj,K2,K3,Ki2,K13,Kasare are the interaction coefficients that describe how the combined effect of ‘two parameters influences tensile strength. Afier establishing the empirical model, validation is necessary to confirm its predictive accuracy. ‘This involves comparing the predicted tensile properties derived from the empirical relationship against actual experimental measurements that were not included in the model development. A robust validation process typically includes several key components 1, Residual Analysis: Assessing the residuals, which are the differences between predicted and actual values, helps identify any systematic errors in the model. Ideally, residuals should be randomly distributed, indicating that the model captures the underlying relationships effectively. 2, Statistical Metrics: Employing statistical metries such as R-squared, adjusted R-squared, and root ‘mean square error (RMSE) evaluates the goodness-of-fit of the model. 19|Page3. Cross-Validation: Conducting cross-validation by partitioning the dataset into training and validation sets allows for an unbiased assessment of the model’s predictive performance. This step ensures that the empirical relationship is not merely overfitted to the experimental data, 4, Sensitivity Analysis: Performing sensitivity analysis helps identify which parameters significantly influence tensile properties. The sensitivity can be quantitatively assessed by calculating the partial derivatives of the empirical mode 5. Graphical Representation: Visualizing the empirical relationship through contour plots or surface plots provides intuitive insights into how variations in the welding parameters affect tensile properties, aiding in practical decision-making, In conclusion, the development and validation of an empirical relationship in the tensile properties investigation of AZ91 magnesium alloy welded using FSW under varied parameters is a critical step in optimizing welding practices. Table 1: Results of ultimate tensile strength of fSW based on design of experiment 110|P agCoded Value Real Value Tensile Strength (MPa) 1 -l -l 900 10 178 178 2 1 -l 200 10 210 210 3 -l | 900 20 169 169 4 1 1 200 20 198 198 5 -l 0 900 15 220 220 6 1 0 200 15 252 252 7 0 -l 050 10 223 223 8 0 1 050 20 210 210 9 0 0 050 15 273 271 10 0 0 050 15 272 271 ll 0 0 050 15 267 271 12 0 0 050 15 269 271 13 0 0 050 15 268 271 3.2 EFFECT OF INPUT PARAMETERS ON THE TENSILE STRENGTH ‘The tensile strength of AZ91 magnesium alloy welded using Friction Stir Welding (FSW) is significantly influenced by various input parameters, including tool rotation speed, welding speed, axial force, and 11 [Pagtool geometry. Understanding the effects of these parameters is essential for optimizing the welding process and ensuring high-quality welds that meet the requirements for various engineering applications. Tool rotation speed plays a critical role in determining the heat generation and material flow during the FSW process. Higher rotation speeds can lead to increased thermal input, which can enhance the ‘material's plasticity, facilitating better mixing and bonding between the base materials. However, excessively high rotation speeds may result in overheating, leading to defects such as voids and reduced tensile strength due to grain coarsening. Conversely, lower rotation speeds may not generate sufficient heat to achieve optimal material flow, potentially resulting in incomplete bonding and weaker welds. Welding speed is another critical factor affecting tensile strength. A higher welding speed generally reduces the heat input, leading to a shorter dwell time of the tool at a given location. This can result in inadequate fusion between the welded components, compromising the mechanical properties ofthe joint. On the other hand, a slower welding speed increases the heat input, which may improve material flow and bonding. However, too slow a speed can also cause overheating, leading to detrimental effects on the microstructure and mechanical properties Axial force, or the downward pressure exerted by the welding tool, is crucial for achieving effective ‘material consolidation during the FSW process. An optimal axial force ensures adequate contact between the tool and the workpieces, promoting effective heat transfer and material deformation. Insufficient axial force can lead to incomplete fusion and increased porosity, adversely affecting tensile strength. Conversely, excessive axial force may induce excessive strain and lead to tool wear or damage, negatively impacting weld quality. Tool geometry, including the shape and design of the tool pin and shoulder, also plays a significant role in the welding process. Different tool geometries influence the flow of material during welding, impacting heat generation and distribution. For instance, a tool with a larger shoulder diameter can ‘generate more heat due to increased contact area, while a tool with a smaller pin diameter may promote finer material mixing and a mote refined microstructure. The choice of tool geometry must therefore be carefully considered to balance heat generation, material flow, and mechanical properties. ‘The interplay of these input parameters leads to complex interactions that ultimately dictate the tensile strength of the welded joints. Experimental studies, often complemented by statistical analysis and modeling techniques such as Response Surface Methodology (RSM), can help elucidate these relationships. By systematically varying the input parameters and measuring the resulting tensile strength, researchers can develop empirical models that predict how changes in welding conditions will affect joint performance, ‘addition to these primary parameters, the interaction effects among them can also significantly influence the tensile strength of AZ91 magnesium alloy welds. For instance, the combined effects of tool rotation speed and welding speed can create optimal thermal profiles that enhance microstructural characteristics. Advanced statistical modeling techniques, such as Response Surface Methodology (RSM), can be utilized to explore these interactions and develop empirical relationships that accurately predict tensile strength based on input parameters, In conclusion, the tensile strength of AZ91 magnesium alloy welded using FSW is significantly influenced by the input parameters of tool rotation speed, welding speed, axial force, and tool geometry. Understanding the effects of these parameters and their interactions is essential for optimizing welding conditions and ensuring high-quality welded joints. Through careful selection and control of input parameters, itis possible to enhance the tensile strength and overall performance of AZ91 magnesium alloy welds, paving the way for their effective application in demanding industries such as aerospace and 112|P agautomotive. Continued research in this area will contribute to the development of more robust welding techniques and improved material performance. | Axial force Shoulder 13 [Pag3.3 MICROSTRUCTURE ANALYSIS Microstructure analysis is a critical aspect of understanding the tensile properties of AZ91 magnesium, alloy welded using Friction Stir Welding (FSW). The microstructural characteristics of welded joints significantly influence their mechanical properties, including tensile strength, ductility, and toughness. By investigating the microstructure, rescarchers can gain insights into the effects of various welding parameters on the material’s behavior and performance. Weld Zone Formation: The FSW process creates distinct zones within the welded joint, each exhibiting ‘unique microstructural features. The primary zones include the stir zone (SZ), heat-affected zone (HAZ), and base metal (BM). The stir zone is characterized by dynamic recrystallization due to the intense ‘mechanical stirring and heat generated during the welding process. This results in a fine-grained ‘mictostructure, which generally contributes to improved tensile properties. Conversely, the heat-affected zone experiences thermal cycles that can lead to coarsening of the microstructure and potential loss of strength, Grain Size and Distribution: One of the critical factors affecting the tensile properties of AZ91 ‘magnesium alloy welds is the grain size within the stir zone. A finer grain structure enhances tensile strength due to the Hall-Petch effect, which states that smaller grains impede dislocation motion, resulting in increased yield strength. Microstructural analysis can be conducted using techniques such as ‘optical microscopy or scanning electron microscopy (SEM) to evaluate grain size and distribution. By varying welding parameters such as tool rotation speed and welding speed, rescarchers can influence the ‘grain refinement and assess its impact on mechanical performance. (a) (b) Phases and Precipitates: The microstructure of AZ91 magnesium alloy typically consists of alpha-Mg (the primary matrix phase) and various intermetallic compounds that can form during the welding. process. These phases can influence the mechanical properties of the weld. For example, the presence of phases like B-Mgl7Al12, which can be detrimental to ductility, may lead to reduced toughness. Analyzing the phase composition and distribution using X-ray diffraction (XRD) of energy-dispersive X- ray spectroscopy (EDX) can provide insights into how different welding parameters affect the formation of these intermetallics and their implications for tensile properties. Effect of Welding Parameters: The microstructural evolution in the welded joints is highly sensitive to the welding parameters employed. For instance, increasing the tool rotation speed can enhance heat input and improve material flow, leading to finer grains in the stir zone, Conversely, excessive heat can lead to grain coarsening and the formation of undesirable phases. Similarly, adjusting the welding speed influences the cooling rate, which can also affect microstructure and phase stability. By systematically 20/P agvarying these parameters and conducting microstructure analysis, researchers can establish correlations between the welding conditions and the resultant microstructural features. Fractography: In addition to microstructure analysis, fractographic studies of failed tensile specimens provide valuable information about the mechanisms of failure and the influence of microstructural features on mechanical performance. Examination of fracture surfaces using SEM can reveal details about the mode of failure (.g., ductile vs, brittle) and provide insights into the effectiveness of the welding parameters. Features such as dimples on ductile fractures indicate good material toughness, while brittle fractures exhibit 2 more planar appearance, suggesting a compromised microstructure. Lic. ine MICROHARDNESS Microhardness testing is a critical aspect of evaluating the mechanical properties of AZ91 magnesium alloy welded joints produced through Friction Stir Welding (FSW). This testing provides valuable insights into the material’s ability to withstand deformation and its overall durability, which are essential for applications in demanding industries such as aerospace and automotive. Understanding the microhardness of welded joints allows researchers to correlate the hardness values with tensile strength and other mechanical properties, ultimately aiding in the optimization of welding parameters, 88 different zones of In the context of AZ91 magnesium alloy, microhardness can vary significantly ac the weld, primarily influenced by the welding parameters employed during FSW. The welded joint typically consists of several distinct regions, including the base metal (BM), heat-affected zone (HAZ), and the weld nugget (WN). Each of these regions exhibits different microstructural characteristics and, consequently, different microhardness values, ‘Weld Nugget: The weld nugget is the region where the most significant material mixing occurs due to the stirting action of the tool. In this zone, the microstructure typically refines because of the dynamic recrystallization process induced by the FSW. This refinement leads to increased hardness in the weld ‘nugget compared to the base metal, as the fine grains enhance the material's strength. The microhardness of the weld nugget can be affected by factors such as tool rotation speed, welding speed, and axial force. 20|P aHigher tool rotation speeds tend to promote better mixing and finer grains, resulting in increased microhardness values Heat-Affected Zone (HAZ): The heat-aflected zone lies adjacent to the weld nugget and experient thermal cycles during welding without undergoing complete melting. The microhardness in the HAZ can vary based on the distance from the weld nugget. Typically, the HAZ shows decreased hardness compared to the weld nugget due to grain coarsening and potential changes in the magnesium alloy’s microstructure. Factors such as cooling rates and the thermal history of the material during welding significantly influence the microhardness in this zone. Optimizing the welding parameters can help ‘minimize the grain coarsening effect in the HAZ, leading to improved hardness and mechanical properties. Base Metal: The base metal’s microhardness remains relatively unaffected by the welding process compared to the other regions. However, itis essential to compare the microhardness values of the base ‘metal with those of the weld nugget and HAZ to assess the overall performance of the welded joint. Understanding how the welding parameters influence the hardness in the base metal can provide insights into how they affect the entire weld quality Influence of Welding Parameters: Various welding parameters impact the microhardness of the welded joints, For instance, an increase in tool rotation speed can lead to higher microhardness in the weld ‘nugget due to enhanced thermal input and more refined microstructure. Similarly, adjusting the welding speed can influence the cooling rate, thereby affecting the hardness in the HAZ and weld nugget. It is also essential to consider the axial force, as appropriate pressure can improve material flow and reduce defects, leading to higher microhardness values. Correlation with Tensile Properties: The microhardness of the welded joints has a direct correlation with their tensile properties. Generally, higher microhardness values in the weld nugget indicate greater tensile strength and resistance to deformation. By conducting a comprehensive analysis of microhardness across different regions of the weld, researchers can establish empirical relationships between hardness and tensile strength, providing valuable data for optimizing FSW processes. 20|P agNX Metllography sample 20|P ag4.CONCLUSION ‘The FSW welding process on Magnesium alloy has been done successfully and the following observations were made: In this research, the tensile properties of AZ91 magnesium alloy welded using Friction Stir Welding (FSW) under varied parameters were systematically investigated. The study demonstrated that optimal welding parameters significantly enhance the mechanical properties of the welded joints, with particular emphasis on tool rotation speed, welding speed, and axial force. Microhardness testing revealed distinct variations across the weld nugget, heat-affected zone, and base metal, correlating with tensile strength results. The refined microstructure in the weld nugget contributed to superior tensile properties, highlighting the effectiveness of FSW in producing high-strength joints in AZ91 magnesium alloys. Methodology (RSM), provided valuable insights into the relationships between input parameters and tensile strength, facilitating the development of predictive models, Furthermore, the findings underscore the importance of precise parameter control in minimizing defects such as porosity and grain coarsening, Overall, this research not only advances the understanding of FSW processes but also provides practical guidance for optimizing welding techniques in industrial applications, paving the way for the broader use of AZ91 magnesium alloys in demanding sectors. Future studies should focus on exploring additional parameters and their effects on long-term performance and fatigue resistance of welded joints. 218|PagML. 12, 13, 14. 15, 16. 17. 5. REFERENCE (1992) ASM handbook. In: Olson DL, et al. (eds) Properties and selection: non-ferrous alloys and special-purpose materials, vol. 2. ASM Intemational, Materials Park Giirel CamI & Given ipckoglu in Recent developments in joining of Magnesium alloys Received: 22 August 2016 /Accepted: 2 December 2016 # Springer-Verlag London 2016 HK. Rafi, G. D. J. Ram, G. Phanikumar and R. K. Prasad: ‘Microstructure and tensile propetties of friction welded Magnesium alloy AA7075-T6", Mater. Des., 2010, 31, 2375-2380. A.A. M. da Silva, E. Arruti, G. Janeiro, E. Aldanondo, P. Alvarez and A. Echeverria: “Material flow and mechanical behaviour of dissimilar AA2024-T3 and AA7075-T6 magnesium alloys friction stir welds’, Mater. Des., 2011, 32, 2021-2027. 1. Sevim, F. Hayat, Y. Kaya, N. Kahraman and S, Sahin: “The study of MIG weldability of heat-treated Magnesium alloys’, Int. J. Adv. Manuf. Technol., 2013, 66, 1825-1834. G. Antonsson: ‘Springer handbook of mechanical engineering’, 656-672; 2008, Berlin, Springer. T. Rosado, P, Almeida, I. Pites, R. Miranda and L. Quintino: “Innovation in are welding’, in ‘Proc. S8Congresso de Engenharia de Moc,ambique’, Maputo, September 1, 1-18; 2008, M. Peel, A Steuwer, M. Preuss, P. J. Withers, Microstructure, mechanical properties and residual stresses as a function of welding speed in xmagnesium AASO83 friction stir welds, J. Acta Materialia, vol. 51, Issue 16(2003) 4791-4801 MM. El-Sayed, A.Y. Shash, M. Abd-Rabou, Finite Element Modeling of Magnesium Alloy AAS083-O Friction Stir Welding Process, Joumal of Materials Processing Technology, vol. 252(2018) 13-24. M. C. Stasik and R. H. Wagoner: ‘Forming of tailor-welded Magnesium blanks’, Int. J Form. Processes, 1998, 1, 9-33. Sahu P K and Pal $ 2015 Multi-tesponse optimization of process parameters in friction stir welded AM20 magnesium alloy by Taguchi grey relational analysisJournal of Magnesium and Alloys 3 36-46 Elrefaey 2015 Sci. Technol, Weld, Join, 20 280-5 G Ipekoglul and G GamI,2 Formation of weld defects in cold metal transfer are welded 7075-16 plates and its effect on joint performance Ipekoglu G, Kiral B G, Brim $ and Gam G 2012 Mater. Tehnol, 46 627-32 ipekogu G, Erim S and Gam G 2014 Int. J. Adv. Manuf. Technol, 70 201-13 ipekoglu G and Gam G 2014 Metall. Mater. Trans. A 45 3074-87. Gungor et al. (2014) is "Mechanical and microstructural properties of robotic Cold Metal Transfer (FSW) welded 5083-H111 and 6082-T651 Magnesium alloys" 219|Pag18, M, Sivashanmugam, S. C, Jothi, T. Kumar and M. Sathishkumar: “Investigation of microstructure and mechanical properties of GTAW and GMAW joints on AA7075 Magnesium alloy’, Int. J. Des. Manuf. Technol, 2009, 3, 56-62 19.M. Sivashanmugam, N, Manoharan, D, Ananthapadmanaban and S, R. Kumar: “Investigation of microstructure and mechanical properties of GTAW and GMAW joints on AA7075 Magnesium alloy’, Int. J. Des. Manuf. Technol., 2009, 3, 56-62. 20. S.C. Wu, X. Yu, R. Z. Zuo, W. H. Zhang, H. L. Xie and J. Z. Jiang: ‘Porosity, element loss, and strength model on softening behaviour of hybrid laser are welded Al-Zn-Mg- Cu alloy with synchrotron radiation analysis’, Weld. J., 2013, 92, 64s-71s. 21. M, Sivashanmugam, K. A, Kumar, R. K. B. Navas and M. A. E. Abamed: ‘Effect of process parameters on tensile strength in gas metal are welded joints aa7075-t6 Magnesium alloy using regression and response surface model’, Int. J. Res. Eng. Technol., 2014, 3, 163-166. 22. Pickin and Young (2006) is ‘welding magnesium alloy". 23. Wang et al. Effect of Heat Input on Microstructure and Mechanical Properties of ‘valuation of cold metal transfer (FSW) process for Magnesium Alloy Welded Joint 220|PagPO & PSOAttainment PONo Graduate Attribute ‘Attained Justification Pol Engineering knowledge Yes This project focuses on understanding the relationship between welding parameters and the resulting joint properties to optimize strength and performance in engincering applications PO2 Problem analysis Yes The challenge in welding 7075 Magnesium alloy with FSW is controlling heat input to avoid defects like porosity, cracking, and adverse microstructural changes, which weaken the joint PO3 Design/Development of solutions Yes RSM and ANOVA using Design Expert software were applied to optimize welding parameters and improve joint quality in 7075 Magnesium alloy welded wit FSW Pod Conduct investigations of complex problems Yes Systematic analysis and experimentation were used to investigate the impact of welding parameters on the microstructural and mechanical properties of 7075 Magnesium alloy joints POs Modern Tool usage Modem tools, including Cold Metal Transfer (FSW) technology and Design Expert software, were used to optimize welding parameters and enhance the quality of 7075 Magnesium alloy welded joints POG ‘The Engineer and society ‘Yes Engineers advance technologies like FSW for welding 7075 Magnesium alloy, enhancing lightweight, strong materials, 221|PagPO.No | Graduate Attribute ‘Attained Environment and Po7 Yes Sustainability Fihical considerations in PO8 | Ethies ‘engineering include ensuring safe welding practices, Collaboration and individual Individual and team contributions were vital in Poo ork Yes: ‘optimizing welding parameters for w high-quality FSW welding of Magnesium alloy. Effective communication is key for conveying _ technical po 10 | Communication Yes information and ensuring collaboration among team members in the FSW welding of Magnesium alloy. Project management and financial oversight were essential for Project management coordinating resoun and Pou and finance Yes budgeting in the — successful implementation of | FSW technology for welding Magnesium alloy. Life-long leaning is vital for engineers to stay updated with 7012 | Lifesong learning Yes advancements in FSW technology and welding techniques, ensuring continuous improvement in practices and outcomes. 222|PagPSONo | Graduate Attribute ‘Avtained Tuslification To analyze and develop solution To analyze, design and ‘that meet industrial needs by develop solutions bs applying welding technologies evciop Soturions oY enhance the quality of Magnesium| PSO 1 | applying the concepts of Yes alloy joints using friction sti Robotics for societal and welding (FSW) industrial needs. To develop innovative solutions To create innovative ideas for realtime manufacturing and solutions for realtime hotles by at challenges by utilizing automation problems in ess hy s Pso2 Yes tools and friction stir welding Manufacturing sector by adapting the automation tools and technologies. (FSW) for welding Magnesium alloy, enhancing efficiency and quality 223|Pag