The feasibility study to join the laser powder bed fused AlSi10Mg alloy sheets using different friction stir welding parameters was investigated in the present work. Fifteen butt-welded joints using varied parametric combinations were developed based on the design of the experiment's approach. An empirical model between the process parameters and tensile strength was developed and used to understand the mechanical behavior of the welded joints w.r.t. the FSW parameters, followed by the attainment of optimized welding conditions using response surface methodology. The results inferred that the weldability was most significantly influenced by the tool rotational speed, followed by the tool tilt angle and tool traverse speed. The microstructure and mechanical properties of the optimized welded joint were compared with the as-built alloy and the welded joint yielding minimum tensile strength. The electron back scattered diffraction analysis revealed the reduction of average grain size of the stir zone of the joints by 21% for the optimized weld, as compared to the as-built alloy. The welded zones of the joints showed a reduction in hardness by 40–50% and formed the stir zone as the weakest link. The parametric combinations of the optimized weld improved the joint efficiency by ≈ 20% compared to the other weld, followed by an improvement in ductility, which was further characterized using scanning electron microscopy.

在目前的工作中，研究了使用不同搅拌摩擦焊参数连接激光粉末床熔融 AlSi10Mg 合金板的可行性研究。根据实验方法的设计，开发了 15 个使用不同参数组合的对焊接头。开发了工艺参数和抗拉强度之间的经验模型，并用于了解焊接接头的机械性能与 FSW 参数的关系，然后使用响应面方法获得优化的焊接条件。结果推断，可焊性受工具转速的影响最显着，其次是工具倾斜角和工具移动速度。将优化后的焊接接头的显微组织和力学性能与制造态合金和产生最小抗拉强度的焊接接头进行了比较。电子背散射衍射分析表明，与成品合金相比，优化焊缝的接头搅拌区平均晶粒尺寸减小了 21%。接头的焊接区硬度降低了 40-50%，并形成搅拌区作为最薄弱的环节。与其他焊缝相比，优化焊缝的参数组合将接头效率提高了 ≈ 20%，随后延展性也有所改善，使用扫描电子显微镜对其进行了进一步表征。电子背散射衍射分析表明，与成品合金相比，优化焊缝的接头搅拌区平均晶粒尺寸减小了 21%。接头的焊接区硬度降低了 40-50%，并形成搅拌区作为最薄弱的环节。与其他焊缝相比，优化焊缝的参数组合将接头效率提高了 ≈ 20%，随后延展性也有所改善，使用扫描电子显微镜对其进行了进一步表征。电子背散射衍射分析表明，与成品合金相比，优化焊缝的接头搅拌区平均晶粒尺寸减小了 21%。接头的焊接区硬度降低了 40-50%，并形成搅拌区作为最薄弱的环节。与其他焊缝相比，优化焊缝的参数组合将接头效率提高了 ≈ 20%，随后延展性也有所改善，使用扫描电子显微镜对其进行了进一步表征。