Weld Quality Comparison Between Fusion Welding And Solid State Welding On AA1100

Nor Aslan, Nur Amirah (2019) Weld Quality Comparison Between Fusion Welding And Solid State Welding On AA1100. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

AA 1100 is widely used in many fields of engineering such as marines, aerospace and automobile. This is because, AA1100 portrays unique properties such as resistance to corrosion, high strength, lightweight, good conductor of electricity and heat and many others. Many types of welding have been proposed by industry in order to join this metal, either from fusion welding or solid state welding. From literature review, one best welding from each type has been compared and selected to be compared on its weld quality on AA1100. The properties of wrought alloy AA1100 that is best undergoes cold worked makes BFSW welding is the best welding to be performed on joining AA1100 rather than TIG welding. Taguchi design of experiment was develop using Minitab software to develop weld run parameter, optimization, regression and validation error. TIG welding parameter which were current (180, 200, and 230 A) and weld speed (12, 13, and 15 cm/min) were selected by previous study and pilot test. While BFSW welding parameter which were rotation speed (800, 900 and 1000 rpm) and weld speed (90, 105 and 150 mm/min) were also selected by previous study and pilot test. The weld quality was compared after optimization parameter weld run by the results on mechanical strength from tensile strength, hardness and weight of weld. Also, the defects and weld time were observed. Throughout the welding process, the weld response which was temperature was recorded using thermocouple to observe the behavior of weld response during the welding process. The optimize parameter for TIG were 230 A and 15 cm/min, while BFSW welding optimize parameter were 800 rpm and 90 mm/min. BFSW wins at every test except for hardness due to filler metal addition in TIG weld. The result was approved by validation error below than 10% which are 7.10% and 0.07% for TIG welding and BFSW welding respectively.

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