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“Investigate the effect of welding process parameters

on mechanical properties of Aluminium alloy weld -AA7075”

By

Dhyey Kalaria
(Enrollment No: -170030728005)

Guided By

Dr. G. D. Achariya
Principal,
AITS, RAJKOT

November 2019

ATMIYA INSTITUTE OF TECHNOLOGY AND SCIENCE


YOGIDHAM GURUKUL, RAJKOT, GUJARAT, INDIA

I
CERTIFICATE
This is to certify that research work embodied in this thesis entitle

“Investigate the effect of welding process parameters on mechanical

properties of Aluminium alloy weld – AA 7075” was carried out by Dhyey

Kalaria [170030728005] at Atmiya Institute of Technology and Science, Rajkot

(003) for partial fulfillment of Master of Engineering degree in Production

Engineering to be awarded by Gujarat Technological University. This research

work has been carried out under my guidance and supervision and it is up to my

satisfaction.

Date:
Place: Rajkot

Guide Co Cuide
Dr. G.D.Acharya Prof Pratik Kikani
Principal Assistant Professor,
AITS Rajkot Mechanical Engineering Department

-------------------------------------------- ----------------------------------------------

Prof. Shivang S.Jani Dr. G.D.Acharya


Head of department, Principal
Mechanical Engineering Department AITS Rajkot

---------------------------------------------- --------------------------------------------

College seal

II
COMPLIANCE CERTIFICATE

This is to certify that the research work embodied in this dissertation titled

“Investigate the effect of welding process parameters on mechanical

properties of Aluminium alloy weld -AA7075” was carried out by Mr. Dhyey

kalaria (170030728005) at Atmiya Institute of Technology and Science, Rajkot

(003) for the partial fulfilment of Master of Engineering Degree to be awarded

by Gujarat Technological University. He has complied to the comments given by

the Dissertation phase I as well as Mid Semester Thesis reviewed to my

satisfaction.

Date:

Place: Rajkot

Dhyey kalaria Dr. G.D.Acharya


(170030728005) Principal
AITS, Rajkot

III
THESIS APPROVAL CERTIFICATE

This is to certify that the research work embodied in this dissertation titled

“Investigate the effect of welding process parameters on mechanical

properties of Aluminium alloy weld -AA7075” was carried out by Mr. Dhyey

kalaria (170030728005) at Atmiya Institute of Technology and Science, Rajkot

(003) is approved for the Degree of Master of Engineering with specialization of

Production Engineering by Gujarat Technological University.

Date:

Place:

Examiner’s sign and Name

--------------------------- ---------------------------

IV
DECLARATION OF ORIGINALITY

We hereby certify that we are the sole authors of this thesis and that neither any part of this
thesis nor the whole of the thesis has been submitted for a degree to any other University or
Institution.

We certify that, to the best of our knowledge, the current thesis does not infringe upon anyone’s
copyright nor violate any proprietary rights and that any ideas, techniques, quotations or any
other material from the work of other people included in our thesis, published or otherwise, are
fully acknowledged in accordance with the standard referencing practices. Furthermore, to the
extent that we have included copyrighted material that surpasses the boundary of fair dealing
within the meaning of the Indian Copyright (Amendment) Act 2012, we certify that we have
obtained a written permission from the copyright owner(s) to include such material(s) in the
current thesis and have included copies of such copyright clearances to our appendix.

We declare that this is a true copy of thesis, including any final revisions, as approved by thesis
review committee.

We have checked write up of the present thesis using anti-plagiarism database and it is in
allowable limit. Even though later on in case of any complaint pertaining of plagiarism, we are
sole responsible for the same and we understand that as per UGC norms, University can even
revoke Master of Engineering degree conferred to the student submitting this thesis.

Date:

Place:

Signature of Student: ___________________ Signature of Guide: ________________

Name of Student: ______________________ Name of Guide: ___________________

Enrollment No: ________________________ Institute Code: ____________________

V
ACKNOWLEDGEMENT

I wish to express my sincere gratitude and regards to my project guide Dr. G. D.

Achariya Under his guidance and support throughout the program has been a major factor in

the successful completion of the present work. This work would not have culminated into the

present form without his valuable suggestions and generous help.

I am thankful to all faculties and friends at ATMIYA INSTITUTE OF TECHNOLOGY

& SCIENCE (003), RAJKOT who not only provided valuable suggestions and constant help

during my work.

Above all, I am forever thankful to my parents for their valuable time and encouragement.

MR. Dhyey Kalaria

(Enrollment No.:170030728005)

A.I.T.S.,RAJKOT

VI
TABLE OF CONTENTS

TITLE PAGE…………………………………………………………………………… I

CERTIFICATE …………………………………………………………………………II

COMPLIANCE CERTIFICATE………………………………………………………..III

THESIS APPROVAL CERTIFICATE…………………………………………………IV

DECLARATION OF ORIGINALITY………………………………………………….V

ACKNOWLEDGEMENTS ………………………..…………………………………..VI

TABLE OF CONTENTS……………………………………………………………… VII

LIST OF FIGURES ………………………………………………………......…………X

LIST OF TABLE……………………………………………………………….……… XII

ABSTRACT……………………………………………………………………..………XIII

Chapter 1 Introduction

1.1 TIG Welding Process………………………………………………………………1

1..1. Principle……………………………………………………………….…..2

1..2. Application……………………………………………………………..….2

1..3. Advantage…………………………………………………………………3

1..4. Disadvantage………………………………………………………………3

1.2 Comparison of TIG, MIG and FSW………………………………………………..4

1.3 Introduction of Aluminum Alloy…………………………………………………...5

1.4 Weld ability of aluminium………………………………………………………….5

1.5 Classification of Aluminum Alloy………………………………………………….6

1.6 Properties and chemical composition of Aluminum Alloy 7075…………………..7

1.6.1 Chemical composition aluminium AA7075…………………………….7

1.6.2 Mechanical properties of aluminium AA7075………………………….8

VII
1.6.3 Physical properties of aluminium AA7075……………………………8

1.7 Application of Aluminum Alloy 7075……………………………………………9

1.8 Specification of TIG Welding Machine………………………………………….10

1.9 Operating Input Parameters of TIG………………………………………………12

1.10 Company Profile……...…………………………………………………...….13

Chapter 2 Literature Review

2.1 literature Review…………………………………………………………....14

Chapter 3 Problem Definition and objectives

3.1 Problem Definition…………………………………………………………………………….25

3.2 Objectives…………………………………………………………………………………………25

3.3 Boundary Conditions………………………………………………………………………..26

Chapter 4 Methodology

4.1 Aluminum Alloy 7075 6-mm Thickness Plate………………………………28

4.2 Spectro Test Sample AA7075…………………………………………….…29

4.3 Chemical Test Report of Aluminum Alloy 7075……………………………29

4.4 Chemical Composition of AA7075………………………………………….31

4.5 AWS Standard Chemical Composition for AA 7075………………………..32

4.6 Filler Metal 5356…………………………………………………………….32

4.7 Chemical Composition of Filler Metal 5356………………………………...33

4.8 Parameters Selection for Work………………………………………………34

4.9 Experimental Design…………………………………………………………34

4.10 Full factorial Method……………………………………………………….35

4.11 Experimental Design in Software…………………………………………..36

4.12 Experimental Design Combinations………………………………………..38

VIII
4.13 Drawing of Tensile Specimen……………………………………………41

4.14 line diagram for sample Specimen……………………………………….41

4.15 sample preparation……………………………………………………….42

4.16 Edge preparation of work piece…………………………………………..42

4.17 Sample For Experiments…………………………………………………43

4.18 Performing Experiments…………………………………………………44

4.19 Welded Specimen………………………………………………………..45

4.20 Dye Penetration………………………………………………………….46

4.21 Hardness Testing…………………………………………………………47

4.22 Tensile Test Specimen…………………………………………………...48

4.23 Performing Tensile Test…………………………………………………48

4.24 After Tensile test specimen………………………………………………49

Chapter 5 Result and Discussion

5.1 Tensile Strength and Hardness Results…………………………………..50

5.2 Regression analysis and Generation of Equations……………………….51

5.3 Validation…………………………………………..…………………….62

Chapter 6 Conclusion and Future Scope

6.1 Conclusion………………………………………………………………...63

6.2 Future scope……………………………………………………………….64

Chapter 7 References…………………………………………………65

Appendix A: Review card

Appendix B: Compliance Report

Appendix C: Paper Submission

Appendix D: Plagiarism Report

IX
List of figures

Figure no List of figures Page No


Fig 1.1 TIG welding diagram 1
Fig 1.2 Specific application of Al 7075 9
Fig 1.3 Magicwave-3000 TIG welding machine 10
Fig 3.1 Boundary Conditions 26
Fig 4.1 Flow Chart of the Proposed Work 28
Fig 4.2 AA 7075 6-mm Thickness Plate 28
Fig 4.3 Spectro Test Sample AA7075 29
Fig 4.4 Material Test Certificate 30
Fig 4.5 AWS Standard AA7075 32
Fig 4.5.1 Filler Metal 5356 32
Fig 4.6 Selection of Full factorial Design 36
Fig 4.7 Select Number of Factor 37
Fig 4.8 Factor and Level Input 37
Fig 4.9 Experimental Design Combinations 38
Fig 4.10 Drawing of Tensile Specimen 41
Fig 4.11 line diagram for sample Specimen 41
Fig 4.12 Sample preparation 42
Fig 4.13 Edge Preparation of Work Piece 42
Fig 4.14 25° Edge of Work Piece 43
Fig 4.15 50° V Butt Joint 44
Fig 4.16 TIG Welding Machine 44
Fig 4.17 Performing Experiments 45
Fig 4.18 Welded Specimen 46
Fig 4.19 Dye Penetration 47
Fig 4.20 Performing Hardness Test 47
Fig 4.21 Tensile Test Specimen 48
Fig 4.22 Performing Tensile Test 48
Fig 4.23 After Tensile Test Specimen 49
Fig 5.1 Select analyse Taguchi design 51
Fig 5.2 Analyse Taguchi design menu for tensile strength 52
Fig 5.3 Analyse Taguchi design Options for tensile strength 52
Fig 5.4 Tensile strength v/s current, Gas flow rate, Groove angle 53

X
Fig 5.5 Hardness v/s Current, Gas flow rate, Groove angle 53
Fig 5.6 Generation of DOE with Results 54
Fig 5.7 Selection of Regression Analysis 55
Fig 5.8 Selection of Responses and Predictors 56
Fig 5.9 Regression Equation for Tensile Strength 56
Fig 5.10 Selection of Hardness as Response 57
Fig 5.11 Regression Equation for Hardness 57
Fig 5.12 Regression Equation for Tensile Strength 58
Fig 5.13 Regression Equation for Hardness 59
Fig 5.14 Selection of Response Optimizer for optimization 60
Fig 5.15 Goal Set to Maximize 60
Fig 5.16 Results of Optimization 61

XI
List of Tables

Table no List of Table Page no


Table 1.1 Comparison of TIG, MIG and FSW 4
Table 1.2 Chemical composition aluminium AA7075 7
Table 1.3 Mechanical properties of aluminium 7075 8
Table 1.4 Physical properties of aluminium 7075 8
Table 1.5 machine specification 11
Table 1.6 Operating input parameters 12
Table 4.1 Chemical Composition of AA7075 31
Table 4.2 Chemical Composition of Filler Metal 5356 33
Table 4.3 Range of Parameters 35
Table 4.4 Experimental Design Combinations 40
Table 5.1 Tensile Strength and Hardness Results 51
Table 5.2 Validation Experiment Results 62
Table 5.3 Comparison of Results 62

XII
“Investigate the effect of welding process parameters
on mechanical properties of Aluminium alloy weld – AA7075”

Submitted by

Dhyey Kalaria
(170030728005)

Supervised by

Dr. G. D. Achariya
Principal
Atmiya Institute of Technology and Science
Rajkot-360005, Gujarat, India

ABSTRACT

Aluminium has very unique properties of light weight and corrosion


resistance and due to this it becomes very interesting metal in the field of
engineering. The purpose of this study is to investigate the effect of welding
process parameters on mechanical properties of Aluminium alloy weld. The
main objectives are to identify best suitable welding process and its parameters
for 6mm aluminium 7075 plate weld, evaluate the effect of process parameters
on weld quality and to validate the result. The main input variables are welding
current, Gas flow rate, Bevel angle. Grey pour Tungsten electrode we have
chosen. The equipment required for the experiment are TIG welding machine,
UTS machine, and Brinell hardness testing machine.

Key Words: Aluminium welding, AA7075, 7075, TIG welding, GTAW, Plate
welding, Hardness, Tensile strength, etc.

XIII

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