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Optimizing Process Parameters for Increasing Corrosion Resistance of Friction Stir Spot Welded Dissimilar Al-5086/C10100 Joints

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Abstract

In this paper, dissimilar aluminium Al-5086/C10100 copper spot joints were made using friction stir spot welding, by varying the significant process parameters such as tool rotational speed, plunge depth and dwell time. Using a central composite design model, twenty experiments were conducted and the welded joints were subjected to corrosion analysis. Using electro-chemical system, polarization tests were conducted and salt fog testing was conducted for 20 h. Empirical relationships were established between the process parameters with the pitting potential and the rate of mass loss. ANOVA was used to evaluate the model’s significance and optimization was done using response surface methodology. It was observed that, at 1112 rpm of tool speed, 2.07 mm of plunging depth and 12.3 s of dwelling period, most positive pitting potential of − 586.86 eV and minimum mass loss of 0.0010234 g occurred. The model was validated with error within three percentage, which indicated high predictability of the developed model.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University College of Engineering, Anna University, Tiruchirappalli, Tiruchirappalli, 620 024, India

    S. Siddharth & T. Senthilkumar

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  1. S. Siddharth
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  2. T. Senthilkumar
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Correspondence to S. Siddharth.

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Siddharth, S., Senthilkumar, T. Optimizing Process Parameters for Increasing Corrosion Resistance of Friction Stir Spot Welded Dissimilar Al-5086/C10100 Joints. Trans Indian Inst Met 71, 1011–1024 (2018). https://doi.org/10.1007/s12666-017-1236-1

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  • DOI: https://doi.org/10.1007/s12666-017-1236-1

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