Multi-objective Optimization of Submerged Friction Stir Welding Process Parameters for Improved Mechanical Strength of AA6061 Weld Bead by Using Taguchi-L18-Based Gray Relational Analysis

Friction Stir Welding is a well known solid state joining technology. Many processing conditions and materials properties affect the microstructural evolution and mechanical behavior of the produced joints. The main parameters involved in the welding process have been studied and the results presented in the present paper. The fatigue life and crack behavior of several aluminum alloys FSW joints have been presented. The analysis was conducted through a multi-objective optimization tool capable of correlating all the material properties and processing parameters to the final mechanical performances of the welds.

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Multi-objective optimization of friction stir welding process parameters for joining of dissimilar AA5083/AA6063 aluminum alloys using hybrid approach

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/1464420715627294 ◽

2016 ◽

Vol 232 (4) ◽

pp. 343-353 ◽

Cited By ~ 6

Author(s):

Saurabh Kumar Gupta ◽

KN Pandey ◽

Rajneesh Kumar

Keyword(s):

Friction Stir Welding ◽

Aluminum Alloys ◽

Process Parameters ◽

Hybrid Approach ◽

Weld Nugget ◽

Multi Objective Optimization ◽

Nugget Zone ◽

Friction Stir ◽

Multi Objective ◽

Dissimilar Aluminum Alloys

Joining of dissimilar aluminum alloys are widely used in automobile, aerospace and shipbuilding industries. The defect-free joining of aluminum alloys using conventional technique is a challenging task for a welding engineer. Friction stir welding has been established as one of the most promising processes for defects-free joining of aluminum alloys. In this study, a hybrid approach of grey relational analysis with principal component analysis, is applied for multi-objective optimization of process parameters for friction stir welding of dissimilar AA5083/AA6063 aluminum alloys. Three responses namely tensile strength, average hardness at weld nugget zone and average grain size at weld nugget zone, and four process parameters with three levels have been selected for the study. Taguchi method based L27 orthogonal array design matrix is used for experiments. The optimal set of process parameters using hybrid approach was found as 900 r/min of tool rotational speed, 60 mm/min of welding speed, 18 mm of shoulder diameter and 5 mm of pin diameter. Improved performance of each response was obtained from the confirmation tests at optimum level of parameters.

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Multi response Optimization of Friction stir welding process parameters in dissimilar alloys using Grey relational analysis

IOP Conference Series Materials Science and Engineering ◽

10.1088/1757-899x/390/1/012061 ◽

2018 ◽

Vol 390 ◽

pp. 012061 ◽

Cited By ~ 1

Author(s):

K Palani ◽

C Elanchezhian

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Grey Relational Analysis ◽

Welding Process ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Relational Analysis ◽

Dissimilar Alloys ◽

Response Optimization ◽

Grey Relational

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An intelligent multi-objective framework for optimizing friction-stir welding process parameters

Applied Soft Computing ◽

10.1016/j.asoc.2021.107190 ◽

2021 ◽

Vol 104 ◽

pp. 107190

Author(s):

Tanmoy Medhi ◽

Syed Abou Iltaf Hussain ◽

Barnik Saha Roy ◽

Subhash Chandra Saha

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Welding Process ◽

Friction Stir ◽

Multi Objective ◽

Friction Stir Welding Process

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Multi objective prediction and optimization of control parameters of Friction stir welding on Casted AlSi10Mg plates with Taguchi – Gray Relational Analysis

Global Journal of Engineering and Technology Advances ◽

10.30574/gjeta.2021.8.1.0095 ◽

2021 ◽

Vol 8 (1) ◽

pp. 001-009

Author(s):

Balakrishna G ◽

B Raghukumar ◽

B Balakrishna

Keyword(s):

Friction Stir Welding ◽

Axial Load ◽

Welding Process ◽

Hardness Test ◽

Gray Relational Analysis ◽

Welding Parameters ◽

Friction Stir ◽

Relational Analysis ◽

Dominant Process ◽

Three Stages

In this study, a 3 mm thickness of AlSi10Mg Casted alloy plates was used in the friction stir welding process. The experimentations were conducted Using design of experiment to shorten the number of experiments and to get optimal friction stir welding parameters by utilizing Gray relational analysis based on the ultimate tensile and hardness test results. Orthogonal array of L9 (33) was used based on three main parameters and three stages for each parameter, where tool velocity of three stages are 800, 900 and 1000 Rpm, tool feed of 30,40,50 mm/min, plus axial load of 300,400 and 500 Kg. Using Minitab 17 software. Gray Relational analysis is used to explore the optimal set of process variables and their effects on the ultimate tensile strength and hardness of weld plates. The plates are effectively welded, tensile test and hardness is measured at room temperature. The end result shows that the tool velocity 1000 rpm, feed 50 mm / min, then axial load of 400 kg are dominant process parameters to join AlSi10Mg Casted alloy plates.

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Multi Response Optimization of Submerged Friction Stir Welding Process Parameters Using Grey Relational Analysis

Volume 2: Advanced Manufacturing ◽

10.1115/imece2016-65797 ◽

2016 ◽

Author(s):

Senthil Kumar Velukkudi Santhanam ◽

Sankar Ramaiyan ◽

Lokesh Rathinaraj ◽

Rathinasuriyan Chandran

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Grey Relational Analysis ◽

Welding Process ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Response Characteristics ◽

Relational Analysis ◽

Response Optimization ◽

Grey Relational

Friction stir welding (FSW) invented by TWI is a solid-state joining process, which is used to weld high-strength aluminum alloys and other metallic alloys which are non weldable by conventional fusion welding process. In this work, AA6063-O alloy of 150 mm in length, 75 mm in width and 6mm thickness is taken and friction stir welded in submerged condition in order to improve the joint properties. The chosen process parameters are tool pin profiles (cylindrical, threaded and tapered), rotational speed and welding speed. The process parameters are optimized with multi response characteristics including hardness and average grain size at the nugget zone. The traditional Taguchi approach is insufficient to solve a multi response optimization problem. Therefore, Grey Relational Analysis (GRA) is used in this current work. The optimal result indicates that the multi response characteristics of the AA6063-O during the submerged friction stir welding process can be enhanced through Grey Relational Analysis. In order to investigate the significance of process parameters, Analysis of Variance (ANOVA) is carried out. The mechanical properties and microstructure variation of both the normal FSW and submerged FSW joints are compared.

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