The Investigation Of Weld Defect Repair Using Friction Stir Addtive Manufacturing

Christine, Sia Li Ling (2020) The Investigation Of Weld Defect Repair Using Friction Stir Addtive Manufacturing. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Weld repair is a common technique in which cracked material is removed by arc gouging, and the components are then welded together to rejoin the material on either side of the crack. The welding process is divided into two categories: fusion welding and solid-state welding. Welding is defined as melting materials together and coalescing by heating. Heat the material at the seam to a molten state and solidify it. Due to the participation of the molten state and solidification, fusion welding has various limitations in the form of metallurgical defects, such as shrinkage, porosity, cracking, deformation, and corrosion. Weld repair is used · to repair defects caused by fusion welding. The use of friction stir additive manufacturing (FSAM) for welding repair is the scope of this study. The purpose of this study is to analyze the available literature of FSAM in welding repair, use the literature results to predict the welding performance of FSAM, and conduct a pilot test of FSAM in a laboratory environment. The material used in this study was AA1100. To simulate welding defects, grinding will be performed on AAl 100 to produce samples. After comparing the literature and making predictions, the tensile strength of FSAM repair welding is predicted to be 121.01 MPa, which is 10.01% higher than the original tensile strength. The microhardness oftbe FSAM repair weld predicted is 49.79 HV, which is 1.42% lower than the original microhardness . All literature studies have shown that repair welding successfully repaired and improved the microstruclure. The pilot test of FSAM repair welding successfully welded the workpiece. However, in the second pilot test, the tool was broken in FSAM. After observing the microstructure, the actual reason should be revealed. In order to suggest the next study, it is best to perform FSAM repair welding on AA 1100 to prove the predicted results. In the research process, the literature research on FSAM repair welding, especially AA1100, is very limited. It shows the novelty of this research

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