Barnik Saha Roy

National Institute of Technology, Agartala | NITA · Department of Mechanical Engineering

The quality as well as efficient welding is crucial to fulfil the consumer satisfaction and getting returns from production, which is mostly depends on weld bead properties for any welding process, which is influence by the selected welding method and its process variables. So, the significant efforts are to choose the appropriate welding process i...

The current study employed the friction stir additive manufacturing (FSAM) method to fabricate three-layered laminated composite by utilizing 3 mm thick sheets of AA6061-T6 alloy (top and bottom layers) and pure Cu (middle layer). The feasibility of FSAM in producing high-performance Al/Cu/Al laminated composites was evaluated by analyzing the infl...

This study focused on enhancing the corrosion resistance of Zn-reinforced, multi-pass friction stir-processed 6 mm AA2024-T3 plates. Influence of FSP passes and Zn microparticle incorporation on composite corrosion behavior in3.5% NaCl solution. Microstructural analysis was performed using optical microscopy (OM) and field-emission scanning electro...

The study investigates the effectiveness of a novel joint configuration, the double-butt-lap (DBL), in friction stir welding (FSW) to join 6-mm-thick AA 6061-T6 plates. Four welds, including a simple square butt (SSB) configuration and three DBL variations (with UB to LB ratios of 1:2, 1:1, and 2:1), were executed. Using consistent parameters, the...

The study comprehensively explores various welding facets for FSW of advanced structural AMC (AA6092/17.5 SiCp-T6) by varying the Tool Rotational Speed (TRS). Thermal variations, force-torque distribution, structural evolution, and joint mechanical characteristics were evaluated. At 1000 rpm, welding temperature increases along the welding directio...

In this research, the effect of tool pin geometry on the development of heat, torque and force during friction stir welding of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) plate by using double shoulder tool was examined. The overarching aim is to investigate a suitable tool pin geometry that can provide a considerable amount of wel...

This study investigates the temperature distribution behavior during friction stir Processing (FSP) of AA6061-T6 plates with varying SiC particle volume fractions (Vf). FSP have been conducted under consistent parameters: a tool rotational speed of 1100 rpm, tool traverse speed of 1.5 mm/s, and tool tilt angle of 2°. Temperature was monitored using...

The study investigates the effectiveness of a novel joint configuration, the double-butt-lap (DBL), in friction stir welding (FSW) to join 6 mm thick AA 6061-T6 plates. Four welds, including a simple square butt (SSB) configuration and three DBL variations (with UB:LB ratios of 1:2, 1:1, and 2:1), were executed. Using consistent parameters, the inv...

As a noble surface modification technique, friction stir processing (FSP) has been established based on the principle of friction stir welding that refines the microstructure and localized plastic deformation of the material. Nevertheless, despite notable technological progress, challenges persist in utilizing FSP to improve material characteristic...

Friction stir additive manufacturing was employed to fabricate a SiC-reinforced AA6061 composite. The tool with a pin length of 4.5 mm (plunge depth of 50% into the lower layer thickness) was used for the experiment. The stir zone consisted of fine, equiaxed grains due to dynamic recrystallisation. Variations in grain size, as well as changes in pr...

This manuscript presents the microstructure and mechanical analysis of Friction Stir Welded joints of Al 6101 (aluminum alloy) and C11000 (copper alloy) plates of 3 mm thickness with and without incorporation of Silver (Ag) and Zinc (Zn) interlayers. Four joints (J1: Al-Cu), (J2 : Al-Ag-Cu), (J3 : Al-Zn-Cu), (J4 : Al-Ag-Zn-Cu), have been made betwe...

The third generation of Al-Li 2050-T84 alloy was primarily used in aerospace industries due to its exceptional potential for weight saving, high strength, and increased fatigue crack growth resistance. In the present research, three different types of tool pin profiles, namely, hybrid, taper threaded, and triangular, were used to join 2050-T84 Al-L...

Aluminium (Al) and copper (Cu) are widely employed in the industry due to their significant corrosion resistance and electrical conductive properties. The simultaneous requirement of different special properties has increased the trend of joining of Al and Cu. The joining of dissimilar materials has arisen as a new challenge in the research field i...

The joined Al-Cu-Li alloys using friction stir welding (FSW) has been widely used in main structural areas of transport aircraft like fuselage, wings, empennage, window and crown frames etc. The various parameters are found to influence the microstructural and mechanical properties of welded samples. In this study, the effect of different tool tilt...

Friction stir welding (FSW) has played a significant role in joining aerospace alloys. During this process, the tool rotational (TRS) speed has been found to significantly affect heat generation compared to other parameters. Therefore, the study has investigated the effect of heat generation on force-torque and mechanical properties at different to...

Natural fibre-reinforced composites are now becoming incredibly common in various products because of their comparable qualities to conventional materials. Due to its availability, superior mechanical qualities, and low cost, banana pseudostem is extensively used in various applications requiring natural fibres. This study investigates the physical...

An investigation was conducted into how the tool rotation speed affected the microstructure and mechanical properties of friction stir processed samples based on AA6061-T6/SiC surface composites. The tool rotated between 700 and 1500 rpm with steps 400 rpm, while the other process variables were kept constant. Visual inspection reveals a sound and...

This manuscript presents the microstructure and mechanical analysis of Friction Stir Welded joints of Al 6101 (aluminum alloy) and C11000 (copper alloy) plates of 3 mm thickness with and without incorporation of Silver (Ag) and Zinc (Zn) interlayers. Four joints (J1: Al-Cu), (J2 : Al-Ag-Cu), (J3 : Al-Zn-Cu), (J4 : Al-Ag-Zn-Cu), have been made betwe...

In this paper, silicon carbide (SiC) particles were successfully inserted into AA6061-T6 aluminium matrix using multi-pass friction stir processing (MPFSP). The effects of MPFSP and SiC particles on temperature distribution, microstructural evolution, and mechanical properties are being investigated in detail. Processing was carried out at a consta...

In the present investigation, low density and high strength aluminum-lithium alloy was joined by friction stir welding (FSW) with a taper threaded tool at different process parameters. The experimental joint was carried out at different fundamental process parameters like tool traverse speed (TTS; 6, 8, and 10 mm/s) at a constant tool rotating spee...

p>The third generation of Al-Li alloy is a significant material, primarily applicable in the aerospace sector due to its low density, high strength, and increased fatigue crack growth resistance properties. In this study, three tools with different pin geometries, such as triangular, threaded taper, and hybrid tool pins (coupled triangular and thre...

Additive Manufacturing (AM), a key component of Industry 4.0 is recently gaining more and more popularity in the major industrial sectors. Friction Stir Additive Manufacturing (FSAM) is a subcategory of AM technology. It employs the principle of solid-state based friction stir welding method to fabricate multi-layered builds by joining layer upon l...

The present research introduces comparatively new scarf joint configuration (SJC) method for friction stir welding (FSW) of AA 6061-T6 plates and explores the impact of different tool rotation speeds (TRS: 500 rpm to 1400 rpm) at constant tool traverse speed (TTS) of 2 mm/s and tool tilt angle (TTA) of 2° on scarf joint weld quality. Scarf joint co...

In this article, the micro-structural evolution and mechanical performance of similar and dissimilar friction stir welded (FSWed) joints of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) plates were studied. All the joints (similar ABS-ABS, PC-PC, and dissimilar ABS-PC) were designed under the same process parameters of tool rotationa...

Al-Li alloy is one of the suitable materials to be used in the aerospace industry due to its unique physical, mechanical, fatigue and corrosion resistance properties. The present study investigates the effect of rotational tool speed (TRS) on force and torque and its consequences on heat input, temperature, microstructure, and mechanical properties...

The present article deals with the friction stir welding and the effect of process parameters on force and torque generation, its distribution and subsequent effect on the microstructure and mechanical characteristics. Acry-lonitrile Butadiene Styrene (ABS) and Polycarbonate plate (PC) with butt joint configuration were welded using a double step s...

The effect of FSP process parameters such as mechanical, microstructural and wear behaviour on A7075/WC surface composites was examined. In the present investigation, 15 wt% WC was used as a reinforcement for producing FSP surface composite through cylindrical tapered tungsten carbide pin tool. It was observed that WC reinforced FSPed surface matri...

In this paper, different tool pin profiles, namely taper-threaded, triangular, and hybrid are used to join 5-mm-thick 2050-T84 Al-Cu-Li alloy by friction-stir-welding. The experiments were conducted using a one-variable-at-a-time approach by varying the geometry of tool pin profile and kept constant values of tool rotational speed, tool traverse sp...

The present research paper deals principally with the aim to achieve high strength through combined effect of incorporation of reinforcement particles in Friction stir scarf welded joints. The idea is implicated on AA6061-T6 plates with scarf angles of 60° and on different volume fraction (vol%) of reinforcement particles. A double pass FSW was per...

In this work, the effect of variation in heat input on friction stir welding of 6 mm thick AA6092/ 17.5 SiCp-T6 aluminum matrix composite joints is analyzed. The effect of heat input on torque and force, time-temperature profile, microstructure and mechanical properties is studied. Heat input to the weld was controlled by varying traverse speed whi...

Friction stir processing (FSP) is a new and exciting technique being extensively explored because of its thermomechanical surface modification which has the capability to enhance the mechanical, microstructural and tribological properties. Various studies were described on friction stir processed aluminium alloys using several reinforcement particl...

The purpose of this study is to determine the influence of scarf joint configuration on friction stir welding (FSW) of as-cast AA7075/TiB2 aluminium matrix composites (AMCs), as well as the effect on mechanical and microstructure aspects. The experiment was conducted by varying the reinforcement weight percent (wt %) in the parent material (6%, 9%,...

The recently developed composite ‘AA6092/17.5 SiCp-T6’ is gradually capturing the attention of the defense and aviation sectors, where various fabrication and material processing are required to accomplish. Considering this emerging demand, it may require to generate a few integrated shapes or micro-slots on this material. Therefore, the responses...

The present research introduces a unique concept of scarf joint technique in friction stir welding (FSW) of aluminum alloy AA 6061-T6 plates and an investigation on weld quality. A new joint configuration with two distinct scarf angles (75° and 60°) was considered in this study. The various aspects of welding were compared with contemporary simple...

The increase in polymer applications has prompted researchers to work on the best method of joining them. Nylon 6 and glass filled Nylon 6 were joined in the present work using friction stir welding. Welding plates were manufactured using an injection molding machine. The experiment was designed with input parameters such as glass filled contents,...

The comprehensive intention of this paper is to evaluate the optimal welding parameters for joining two dissimilar materials by friction stir welding (FSW) process which is termed as a green manufacturing technology in order to generate quality joints. Conventionally, the optimization of process parameters experimentally is carried out by a time-co...

In this experimental work, pin-on-disc set up were used to study the tribological behavior of Glass Filled (GF) Nylon 6 composite on polymer/polymer and polymer/ AISI D2 steel disc (SD) contacts under dry conditions. Load (N) and sliding speed (m/s) are the factors considered for the test and the output studied was Coefficient-of-Friction (COF), Sp...

The current study investigates the influence of tool tilt angle (TTA) on the mechanical strength of friction stir welded aluminum matrix composite (AMC). Aerospace-grade AA6092/ 17.5 SiCp- T6 plates of 6 mm thickness have been welded at different TTA of 1̊, 2̊ and 3̊ with fixed tool rotational speed of 1000 rpm and tool traverse speed of 1 mm/s. A...

A recently developed spot joining process namely dieless friction stir riveting is explored for understanding the effect of multi-hole configurations on the joint formation in dissimilar grades of aluminum alloy sheets. These spot joints are strengthened by mechanical interlocking together with metallurgical bonding and possesses the absence of hoo...

The current investigation is a preliminary approach proposing the feasibility of a modified joint configuration namely double-butt-lap (DBL) in the field of friction stir welding (FSW). The main scope of adopting this kind of joint configuration is to essentially eliminate the irregularities in material flow and defects (root gap, kissing bond) tha...

In the present study, AA7075/TiB 2 aluminium metal matrix composite (AMCs) was prepared by stir casting method using in-situ reactions of inorganic salts KBF 4 and K 2 TiF 6 . In this process AA7075 alloy is reinforced with different weighted percentages of (5 %wt, 10 %wt, and 15 %wt) Titanium Diboride (TiB 2 ) particles. X-ray Diffraction (XRD) in...

The current investigation is a preliminary approach proposing the feasibility of a modified joint configuration namely double-butt-lap (DBL) in the field of friction stir welding (FSW). The main scope of adopting this kind of joint configuration is to essentially eliminate the irregularities in material flow and defects (root gap, kissing bond) tha...

The paper focuses on developing a novel decision-making model, to select the best welding parameters for friction stir welding of dissimilar aluminium to copper plates. A set of 21 experiments are carried out based on a d-optimal design matrix. Apart from considering the rotational speed and traverse speed as input variables, the position of alumin...

The aim of the study is to investigate the consequences of tool traverse speed on force and torque distribution of friction-stir-welded third-generation Al–Cu–Li alloy joints. The microstructure and corresponding mechanical properties of the joints are investigated on force and torque perspective. Thus, the contribution of the present work lies in...

Dissimilar friction stir welding between 6061-T6 Al alloys to AZ31B Mg alloys with a plate thickness of 6 mm was investigated. Defect-free welds were obtained at a different rotational speed ranging from 400 to 700 rpm with welding speed of 0.5–0.8 mm/sec, respectively. The influence of welding speed and rotational speed was investigated to reveal...

Lap joints of AA 6061-T6 and pure copper are done by friction stir welding at different welding speed and tool rotational speed. The study has been done on the microstructure and mechanical properties of the welded specimens. The microstructure of the welded specimens shows the fine grains in the nugget zone (NZ) and elongated grains in the thermo-...

The present study investigates the effect of parametric variations on microstructural and mechanical properties of friction stir welded (FSW) 6 mm thick as-cast AA6061/SiC Aluminum Matrix Composite (AMC) joints. The study has been designed by varying the traverse speed, tool rotational speed and tilt angle up to various levels. Microstructural inve...

In the present investigation AA7075 alloy reinforced with varying the weight % (wt.%) (6%, 9% and 12%) of Titanium diboride (TiB2) were prepared AA7075/TiB2 AMCs by stir casting method using in situ reaction of K2TiF6 and KBF4 salts. For phase analysis of composite material, X-ray diffraction analysis was performed to determine the presence of TiB2...

In this current research work the joining of Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate (PC) plate were joined by Friction Stir Welding (FSW). The tool used for this was made of H13 steel which has a taper pin profile. This study assesses the impact of using double shoulder tool for joining dissimilar polymers and it was compared with...

5 mm thick AA2050-T84 plates were joined successfully with four different traverse speed (from 1 mm/s to 4 mm/s) by friction stir welding (FSW). Other process parameters were kept constant such as tool rotational speed (TRS) 600 rpm and tool tilt angle (TTA) 1.5° during FSW. A non-consumable, left-hand taper threaded tool made of H13 steel was used...

Friction Stir Welding is an advanced solid state joining process invented as an alternative to join materials which are unfavourable to join using fusion welding technique. In Friction Stir Welding, the non-consumable tool is rotated and is slowly dived into the centreline and simultaneously progressed along that line. The heat generation in the pr...

In the present work tribological properties of polymer/polymer and polymer/steel contacts were studied under dry conditions using a pin-on-disc machine. Acrylonitrile Butadiene Styrene (ABS) pin specimen was tested for friction and wear against AISI D2 steel disc and against ABS disc. The effects of different applied load, sliding velocity at const...

Friction Stir Welding (FSW) is a solid-state manufacturing process that has remarkably enhanced the joint quality of the Al-Mg dissimilar joint. In this paper, a spick-and-span joint configuration has been introduced that has impressively welded modified joint configuration. While welding precise control of welding parameters and plate setup are th...

The present study investigates the effect of parametric variations on microstructural and mechanical properties of friction stir welded (FSW) 6 mm thick as-cast AA6061/SiC Aluminum Matrix Composite (AMC) joints. The study has been designed by varying the traverse speed, tool rotational speed and tilt angle up to various levels. Microstructural inve...

The present investigation reports the effect of Titanium diboride (TiB2) reinforcement on microstructure and mechanical properties of friction stir welded 6 mm thick AA7075/TiB2 as-cast aluminum matrix composite (AMC) joints. The study has been designed by varying the weight % (wt%) of reinforcement (6%, 9% and 12%) in the base material plate and w...

Nylons are high-performance, semi-crystalline thermoplastics with many attractive properties like chemical, physical, and mechanical properties. The aim of this research work is to investigate the feasibility of glass filled Nylon 6 composites by Friction stir welding (FSW). Glass filled Nylon 6 composites were fabricated by an injection molding pr...

Al–Cu joints are used in the electrical industry because of its unique mechanical, thermal and corrosion resistance properties. The present investigation concentrates on understanding the influence of traverse speed on friction stir welded butt joints of 3-mm-thick AA 6061-T6 and pure copper. The welds were produced by varying the traverse speed (3...

Friction Stir Welding (FSW) is one of the most efficient joining process for joining of plastics. The aim of the present work is to introduce the concept of a double step shoulder over the conventional single shoulder tool to eliminate the effect of excessive flashing of polymers and investigate the suitable process parameters for FSWed dissimilar...

A new spot joining process called dieless friction stir extrusion is proposed, in which simultaneous mechanical interlocking (collar formation) and metallurgical bonding is the key aspect of joint formation. The pinless flat stir tool eliminates pinhole and hook formation, the common defects of friction stir spot welding. Aluminum alloy sheets such...

This study investigates the effect of tool rotational speed (TRS) on particle distribution in nugget zone (NZ) through quantitative approach and its consequences on the mechanical property of friction stir welded joints of AA6092/17.5 SiCp-T6 composite. 6 mm thick plates are welded at a constant tool tilt angle of 2� and tool traverse speed of 1 mm...

This article appeared in a journal published by Elsevier. The attached copy is furnished to the author for internal non-commercial research and education use, including for instruction at the author's institution and sharing with colleagues. Other uses, including reproduction and distribution, or selling or licensing copies, or posting to personal,...

Polymer matrix composites (PMCs) are replacing traditional metals and unfilled polymers due to their superior properties such as excellent strength/stiffness-to-weight ratio with enhanced toughness and low cost. Friction stir welding (FSW) is a new addition for joining of plastics and it has many advantages when compared with traditional joining pr...

The process of production and joining of traditional materials is well established however a lot more research is needed in the field of composite materials. Generally, by conventional methods, the probability of producing a blemish metal matrix composite (MMC) is high which is undesirous. Hence, the prime challenges are the production of a defect-...

In the present study, Induction welding was carried out to achieve the joining between dissimilar metals such as mild steel (AISI 1015) and copper (Cu) in open atmosphere with different loads and different current settings. Microstructural evaluation of the welded joints was done by optical microscope and scanning electron microscope (SEM). The stu...

The present review paper focuses on the various researches done in joining of aluminium and copper by friction stir welding (FSW). Being a solid state process, FSW has proven to efficiently join aluminium and copper which is extensively used in power generation, electrical and electronic industry. However, it is a challenge to achieve a good qualit...

The present review paper focuses on the various researches done in joining of aluminium and copper by friction stir welding (FSW). Being a solid state process, FSW has proven to efficiently join aluminium and copper which is extensively used in power generation, electrical and electronic industry. However, it is a challenge to achieve a good qualit...

Friction stir welding (FSW) has evolved as a very promising joining process for light weight material fabrication. Weld characteristics of FSW AA6061-T6 samples in terms of mechanical properties of weldment have been studied by varying the tool tilt angles for taper and taper threaded tool. Torque and different forces (Z force, X force) generated a...

To understand the friction stir welding process, it is very important to know the nature of the material flow in and around the tool. The process is a combination of both thermal as well as mechanical work i.e it is a coupled thermo-mechanical process. Numerical simulations are very much essential in order to obtain a complete knowledge of the proc...