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Friction Stir Welding is a solid-state process where a tool which is not consumable rotates between two metals or alloy. In FSW process heat is generated because of the friction that is developed between the tool and the work piece below the melting point of the material. Compared to conventional welding this FSW process can be used for welding alloys such as aluminium, copper, etc. In this process, we can even weld two different types of alloy together which is not possible in conventional welding. Aluminium alloy AA7075 (Al-Zn-Mg-Cu) is a type of alloy which shows high strength and corrosive resistant because of the zinc content in the alloy. This zinc act as a sacrificial anode for the alloy which forms a outer covering on the surface of the alloy which is the one which gets corroded first and then followed by the alloy. In this FSW the parameters play the significant role that determines the weld characteristics. Here, aluminium alloy of series AA7075 of thickness 6mm is welded by Friction Stir Welding Process. This alloy contains zinc with a minimum amount of 5.8%. This zinc acts as a sacrificial-anode in sub-marines application, where this zinc forms like an outer covering layer on the surface of the submarine. So, this zinc gets corroded first keeping the sub-marine safe for a long period. After the Friction Stir Welding Process is completed, different tests are performed in the welded portion of the alloy. The test starts with the Ultimate Tensile Test followed by the Impact hardness test and the microstructure of the welded portion is studied. The welding parameter such as rotational speed, transverse speed is optimized in this process by using the Taguchi analysis. Taguchi method greatly improves the design and engineering productivity. This method is very effective on regard of its simple experimental design and systematic approach to produce better quality at lower costs. The optimum results can be obtained by providing the input functions and can easily produce better results. By this effect of input variables the results can be formed by S/N ratio and response means. The Larger is better criteria is employed to our problems.

Characteristic Study of Friction Stir Welding of Aluminium Alloy AA7075 Using H13 Surface Hardened Tool Steel with Variable Tool Pin Design