Multiple Response Optimization Studies for Dissimilar Friction Stir Welding Parameters of 6061 to 7075 Aluminium Alloys

2019 ◽  
Vol 16 ◽  
pp. 405-412
Author(s):  
S. RaviKumar ◽  
R. KajaBanthaNavas ◽  
Padakandla Sai Sujeeth
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Welding Parameters ◽  
Multiple Response ◽  
Friction Stir ◽  
Multiple Response Optimization ◽  
Dissimilar Friction Stir Welding ◽  
Response Optimization

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

Friction Stir Welding of Elements Made of Cast Aluminium Alloys

2014 ◽  
Vol 59 (1) ◽  
pp. 385-392
Author(s):  
B. Rams ◽  
A. Pietras ◽  
K. Mroczka
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Aluminium Alloys ◽  
Welding Parameters ◽  
Process Conditions ◽  
Friction Stir ◽  
Seam Weld ◽  
Cast Aluminium ◽  
Weld Structure ◽  
Welding Stability

Abstract The article presents application of FSW method for joining elements made of cast aluminium alloys which are hardly weldable with other known welding techniques. Research’s results of plasticizing process of aluminium and moulding of seam weld during different FSW process’ conditions were also presented. Influence of welding parameters, shape and dimensions of tool on weld structure, welding stability and quality was examined. Application of FSW method was exemplified on welding of hemispheres for valves made of cast aluminium alloy EN AC-43200.

Multiple Response Optimization with Grey Relational Analysis of Friction Stir Welding Parameters in Joining Dissimilar Aluminium Alloys by Taguchi Method

2014 ◽  
Vol 592-594 ◽  
pp. 555-559 ◽  
Author(s):  
S. Ravikumar ◽  
V. Seshagiri Rao ◽  
V. Pranesh
Keyword(s):  
Grey Relational Analysis ◽  
Aluminium Alloys ◽  
Welding Process ◽  
Welding Parameters ◽  
Friction Stir ◽  
Relational Analysis ◽  
Novel Approach ◽  
Grey Relational Grade ◽  
Response Optimization ◽  
Grey Relational

This paper presents a novel approach for the optimization of welding parameters on dissimilar friction stir welded joints between AA6061T-651 and AA7075T-651 aluminium alloys with multiple responses based on orthogonal array by grey relational analysis. Experiments are conducted by varying the welding parameters related to three pin profiles. In this study, welding parameters namely rotational speed, welding speed and pin profiles are optimized with the considerations of multi responses such as ultimate tensile strength and hardness. A grey relational grade is obtained from the grey analysis. Based on the grey relational grade, optimum levels of parameters have been identified and significant contribution of parameters is determined by ANOVA (Analysis of Variance). Confirmation test is conducted to validate the test result. Experimental results have shown that the responses in welding process can be improved effectively through this novel approach.

Optimization of friction stir welding parameters using multiple response surface methodology

2015 ◽  
Vol 231 (7) ◽  
pp. 571-583 ◽  
Author(s):  
Morteza Ghaffarpour ◽  
Ahmad Aziz ◽  
Taha-Hossein Hejazi
Keyword(s):  
Response Surface Methodology ◽  
Friction Stir Welding ◽  
Response Surface ◽  
Welding Parameters ◽  
Multiple Response ◽  
Good Correspondence ◽  
Industrial Systems ◽  
Friction Stir ◽  
Multiple Response Surface Methodology ◽  
The Impact

Improving quality in today’s complicated industrial systems is gaining more and more importance every day. Since applying these systems costs a lot, companies should try to offer the best outcomes and processes possible. One of the products most applied is Tailor Welding Blanks, which is widely used in automobile, aerospace, and other industries. One of the best methods of producing Tailor Welding Blanks is Friction Stir Welding. Using this technology, sheets dissimilar in material and thickness can be joined. In this paper, the possibility of welding thin sheets of 5083-H12 and 6061-T6 aluminum alloy by Friction Stir Welding with the thickness of 1.5 mm is examined. To detect the impact of Friction Stir Welding parameters, i.e. rotational speed (r/min), linear speed (mm/ min), shoulder diameter (mm), and tilt angle (°), a Box-Behnken design was used and using multiple Response Surface Methodology values of robust optimization of tensile strength and elongation were derived. The optimization and experiment results were then compared. The results of the comparison showed a good correspondence.

Underwater dissimilar friction stir welding of aluminum alloys: Elucidating the grain size and hardness of the joints

2017 ◽  
Vol 233 (4) ◽  
pp. 763-775 ◽  
Author(s):  
Khosro Bijanrostami ◽  
Reza Vatankhah Barenji
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Classical Equation ◽  
Hardness Test ◽  
Traverse Speed ◽  
Welding Parameters ◽  
Friction Stir ◽  
Dissimilar Friction Stir Welding ◽  
Electron Microscopes

Underwater dissimilar friction stir welding of the AA6061 and AA7075 aluminum alloys was performed in this study. The effect of friction stir welding parameters on the grain size and hardness of the joints was studied using empirical models. The microstructure of the joints was characterized by means of light and transmission electron microscopes. The Vickers hardness test was conducted to measure the hardness of the joints. In addition, the process parameters including traverse and rotational speeds, grain size and hardness of the joints were correlated. The results revealed that the developed models predicted the hardness and grain size of the joints, precisely. Higher traverse speed and lower rotational speeds resulted in finer grain size and larger hardness. The grain boundaries and dislocations were identified as responsible for the higher hardness of the joints welded at lower heat input conditions. Moreover, the Hall–Petch relationship showed a deviation from its linear classical equation, which was due to the formation of substructures such as dislocations inside the grains.

scholarly journals Studies on Effect of Tool Design and Welding Parameters on the Friction Stir Welding of Dissimilar Aluminium Alloys AA 5052 – AA 6061

2014 ◽  
Vol 75 ◽  
pp. 93-97 ◽  
Author(s):  
V. RajKumar ◽  
M. VenkateshKannan ◽  
P. Sadeesh ◽  
N. Arivazhagan ◽  
K. Devendranath Ramkumar
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Tool Design ◽  
Welding Parameters ◽  
Friction Stir
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