Predicting the ultimate tensile strength and wear rate of aluminium hybrid surface composites fabricated via friction stir processing using computational methods

2021 ◽  
pp. 1-20
Author(s):  
AnandhaKumar C. J. ◽  
Gopi S. ◽  
Dhanesh G. Mohan ◽  
ShashiKumar S.
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Wear Rate ◽  
Computational Methods ◽  
Friction Stir Processing ◽  
Friction Stir ◽  
Surface Composites

scholarly journals Effect of Friction Stir Processing on Gas Tungsten Arc-Welded and Friction Stir-Welded 5083-H111 Aluminium Alloy Joints

2019 ◽  
Vol 2019 ◽  
pp. 1-14 ◽  
Author(s):  
Sipokazi Mabuwa ◽  
Velaphi Msomi
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Aluminium Alloy ◽  
Friction Stir Processing ◽  
Welded Joints ◽  
Ultrafine Grain ◽  
Dimple Size ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Gas Tungsten

This paper presents the analysis of the friction stir-processed aluminium alloy 5083-H111 gas tungsten arc-welded and friction stir-welded joints. The comparative analysis was performed on the processed and unprocessed gas tungsten arc-welded and friction stir-welded joints of similar aluminium alloy 5083-H111. The results showed a clear distinction between the friction stir processed joints and unprocessed joints. There is a good correlation observed between the microstructural results and the tensile results. Ultrafine grain sizes of 4.62 μm and 7.177 μm were observed on the microstructure of the friction stir-processed friction stir-welded and gas tungsten arc-welded joints. The ultimate tensile strength for friction stir-welded and gas tungsten arc-welded before friction stir processing was 153.75 and 262.083 MPa, respectively. The ultimate tensile strength for friction stir processed friction stir-welded joint was 303.153 MPa and gas tungsten arc-welded joints one was 249.917 MPa. The microhardness values for the unprocessed friction stir-welded and gas tungsten arc-welded joints were both approximately 87 HV, while those of the friction stir-processed ones were 86.5 and 86 HV, respectively. The application of friction stir processing transformed the gas tungsten arc morphology from brittle to ductile dimples and reduced the ductile dimple size of the unprocessed friction stir-welded joints from the range of 4.90–38.33 μm to 3.35–15.59 μm.

Effect of Process Parameters on Defect Formation in Friction Stir Processed 6082-T6 Aluminium Alloy

2012 ◽  
Vol 232 ◽  
pp. 3-7
Author(s):  
Akinlabi Esther Titilayo ◽  
Akinlabi Stephen Akinwale
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Feed Rate ◽  
Rotational Speed ◽  
Defect Formation ◽  
Processing Parameters ◽  
Friction Stir

This paper reports the effects of processing parameters on defects formed during friction stir processing of 6082-T6 Aluminium Alloy. The plates were processed by varying the feed rate between 50 and 250 mm/min, while the rotational speed was varied between 1500 and 3500 rpm to achieve the best result. It was observed that the sheets processed at the highest feed rate considered in this research resulted in wormhole defect. These processed samples with defects were correlated to the tensile results and it was found that the Ultimate Tensile Strength (UTS) of these samples was relatively low compared to other samples without defects.

Influences of Tool pin Profile on Microstructure and Mechanical Properties of Al/Cu Composites Fabricated via Friction Stir Processing

2011 ◽  
Vol 383-390 ◽  
pp. 2753-2758
Author(s):  
Amir Mostafapour Asl ◽  
Saeed Mahmoodi Darani ◽  
Mohamad Kazem Besharati Givi ◽  
Arash Aghagol
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Tensile Properties ◽  
Friction Stir Processing ◽  
Metal Matrix ◽  
The Other ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

Friction stir processing (FSP) was used to fabricate Al/Cu metal matrix composite (MMC). The effects of two different tool pin profiles (straight cylindrical and square) and the number of FSP passes on microstructure, tensile properties and microhardness were studied. The results indicated that good dispersion of micro-sized Cu particles, finer grains, higher tensile properties and higher microhardness, can be achieved by the square tool pin profile compared to the samples produced by the other tool. Also it was observed that the ultimate tensile strength of the samples produced by two FSP passes, as a result of Cu particles shattering, increased intensively compared to the samples fabricated with first FSP pass. Further FSP passes increased the elongation of the composites without any considerable changes in yield and ultimate tensile strength.

scholarly journals Optimization of Friction Stir Processing Parameters for Aluminum Alloy (AA6061-T6) Using Taguchi Method

2019 ◽  
Vol 12 (1) ◽  
pp. 1-6 ◽  
Author(s):  
Muna K. Abbassa ◽  
Noor Alhuda B. Sharhan
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Ultimate Tensile Strength ◽  
Taguchi Method ◽  
Friction Stir Processing ◽  
Thick Plate ◽  
Processing Parameters ◽  
Friction Stir ◽  
Tool Tilt Angle

This work is devoted toward optimization of the parameters of the friction stir processing (FSP) which effect on tensile strength of aluminium alloy AA6061-T6 of 6mm thick plate by applying a certain number of tests utilizing the Taguchi method. Design of experiment (DOE) has been applied for the determination of the most important parameters influencing ultimate tensile strength. FSP was achieved under three different rotation speeds (800,1000 and 1250) rpm, different transverse speeds (16,25 and 32) mm\min, and number passes(1,2 and 3)  in the same direction and tool tilt angle was 2°  with using threaded cylindrical pin profile.  The best FSP parameters were 1250 rpm and 32 mm\min and two passes. It was found that the higher hardness value was 75HV in stir zone center and then decreases toward the TMAZ, HAZ and the base metal

Predicting the wear rate of AA6082 aluminum surface composites produced by friction stir processing via artificial neural network

2019 ◽  
Vol 16 (2) ◽  
pp. 409-423
Author(s):  
Isaac Dinaharan ◽  
Ramaswamy Palanivel ◽  
Natarajan Murugan ◽  
Rudolf Frans Laubscher
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Wear Rate ◽  
Friction Stir Processing ◽  
Aluminum Surface ◽  
Content Type ◽  
Friction Stir ◽  
Surface Composites ◽  
Input Parameters ◽  
Artificial Neural

Purpose Friction stir processing (FSP) as a solid-state process has the potential for the production of effective aluminum matrix composites (AMCs). In this investigation, various ceramic particles including B4C, TiC, SiC, Al2O3 and WC were incorporated as the dispersed phase within AA6082 aluminum alloy by FSP. The wear rate of the composite is then investigated experimentally by making use of a design of experiments technique where wear rate is evaluated as the output parameter. The input parameters considered include tool rotational speed, traverse speed, groove width and ceramic particle type. An artificial neural network (ANN) simulation was then used to describe the wear rate of the surface composites. The weights of the network were adjusted to minimize the mean squared error using a feed forward back propagation technique. The effect of the individual input parameters on wear rate was then inferred from the ANN models. Trends are presented and related to the associated microstructures observed. The TiC infused AMC displayed the lowest wear rate whereas the Al2O3 infused AMC displayed the highest, within the scope of the current investigation. The paper aims to discuss these issues. Design/methodology/approach The paper used ANN for the research study. Findings The finding of this paper is that the wear rate of AA6063 aluminum surface composites is influenced remarkably by FSP parameters. Originality/value Original work of authors.

Multi Response Optimization of Friction Stir Processing Parameters on Cryo-Rolled AZ31B Alloys

2020 ◽  
Author(s):  
Senthil Kumar Velukkudi Santhanam ◽  
Jeffrin Michael Gnana Anbalagan ◽  
Shanmuga Sundaram Karibeeran ◽  
Dhanashekar Manickam ◽  
Ramaiyan Sankar
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Processing Parameters ◽  
Friction Stir ◽  
Fine Grain ◽  
Pin Geometry ◽  
Az31b Alloy ◽  
Tool Pin

Abstract Friction stir processing (FSP) method is a solid-state technique used for microstructural alteration and enhancing mechanical properties of sheet metals and as-cast materials. Aluminium, brass, copper, steel, tin, nickel, magnesium and titanium are the widely used materials in friction stir processing. Even though magnesium has low density compared to aluminium, only few reports are made on magnesium. Two stage of process was carried out on the experiment to obtain fine grain refinement and improved strength. First, Cryo-rolling processing on 6mm thickness AZ31B alloy at constant roller power, roller rotation speed, strength coefficient and strain exponent. AZ31B alloy is dipped in liquid nitrogen for certain period and rolled in it’s cold state. Number of passes into roller was same for 9 samples. Cryo-rolled AZ31B is used as sample for the second stage i.e., Friction stir processing. FSPed material produce refined grain structure, micro-structurally modified cast alloys by alloying specific elements, and improvement in material strength. Based on Process parameters the properties of the material alters. Friction stir processing was performed on cryo-rolled AZ31B magnesium alloy with various processing parameters. The effect of process parameters (tool pin geometry, tool rotational speed and tool traverse speed) on two responses namely ultimate tensile strength and micro-hardness values were measured. The tool used for Friction stir processing is H13 high carbon steel with hardness upto 60 HRC. Tool pin geometry used for Friction stir processing are square, cylinder and tapered. The processed materials are cut using wire cut EDM as per ASTM standards to measure the ultimate tensile strength and hardness. Universal tester and Vickers hardness tester were used to measure the tensile strength and hardness of the Friction stir processed sample. Most of the research has been published on cryo-rolled and FSP experiments separately. In this work, a combination of these two process is developed for improved tensile strength, hardness, and ultrafine grain refinement. A multi-response optimization was performed using grey relation analysis (GRA) to find out the optimum combination of the process parameters for maximum ultimate tensile strength hardness. Analysis of variance (ANOVA) and F-test were performed to determine the most significant parameters at a 95% confidence level. The corrosion test was made on Friction stir processed cryo-rolled AZ31B alloy for every process parameters. Salt spray test was done as per ASTM standard to find the corrosion rate. The corrosion rate for Friction stir processed cryo-rolled material is less (at optimal condition). The microstructure analysis was done on the samples using a Scanning Electron Microscopy. For clear view of grains the material is subjected to polishing and etching. The etchant used on the material is Picral + Acetic acid + Hydrogen peroxide. Fine grain size was obtained on the Friction Stir processed Cryo-rolled AZ31B magnesium alloy at optimal condition.

scholarly journals Surface Composites Preparation of AL5052 Reinforced with Al2O3 by Friction Stir Processing

2019 ◽  
Vol 8 (2) ◽  
pp. 3979-3983 ◽  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Processing ◽  
Base Material ◽  
Welding Process ◽  
The Other ◽  
Friction Stir ◽  
Surface Composites ◽  
Proportional Relationship ◽  
Tool Pin

Friction stir processing is a modified form of friction stir welding process which is introduced to prepare the surface composites or to repair the defects in the surface to enhance the mechanical properties. The process is a green and environmental friendly process, where the required heat is produced by frictional action. In the present work, Surface composites were prepared using Al 5052 as base material and Al2O3 as reinforcement particles. Parameters such as number of passes, spindle speed, feed rate and tool pin profile were taken in three different levels. Six tools were made, three tools with 3:1 and remaining three with 4:1 D to d ratio. Totally 18 experiments were conducted with two group of tools. The results were analyzed to study the influence of above mentioned parameters on mechanical properties like tensile strength, hardness. The results were compared for different D/d ratios. The experimental results revealed that 3:1 D/d ratio tools were given better results than 4:1.Tool with square pin profile given better hardness and strength than the other profiles. This is because of the pulsating effect of the square pin profile. The other parameters have directly proportional relationship up to certain level, after which further increase of parameters reduces the tensile strength and hardness.

An appraisal of characteristic mechanical properties and microstructure of friction stir welding for Aluminium 6061 alloy – Silicon Carbide (SiCp) metal matrix composite

2019 ◽  
Vol 13 (4) ◽  
pp. 5804-5817
Author(s):  
Ibrahim Sabry
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Welded Joint ◽  
Rotation Speed ◽  
Fusion Welding ◽  
Friction Stir ◽  
Al 6061

It is expected that the demand for Metal Matrix Composite (MMCs) will increase in these applications in the aerospace and automotive industries sectors, strengthened AMC has different advantages over monolithic aluminium alloy as it has characteristics between matrix metal and reinforcement particles.  However, adequate joining technique, which is important for structural materials, has not been established for (MMCs) yet. Conventional fusion welding is difficult because of the irregular redistribution or reinforcement particles.  Also, the reaction between reinforcement particles and aluminium matrix as weld defects such as porosity in the fusion zone make fusion welding more difficult. The aim of this work was to show friction stir welding (FSW) feasibility for entering Al 6061/5 to Al 6061/18 wt. % SiCp composites has been produced by using stir casting technique. SiCp is added as reinforcement in to Aluminium alloy (Al 6061) for preparing metal matrix composite. This method is less expensive and very effective. Different rotational speeds,1000 and 1800 rpm and traverse speed 10 mm \ min was examined. Specimen composite plates having thick 10 mm were FS welded successfully. A high-speed steel (HSS) cylindrical instrument with conical pin form was used for FSW. The outcome revealed that the ultimate tensile strength of the welded joint (Al 6061/18 wt. %) was 195 MPa at rotation speed 1800 rpm, the outcome revealed that the ultimate tensile strength of the welded joint (Al 6061/18 wt.%) was 165 MPa at rotation speed 1000 rpm, that was very near to the composite matrix as-cast strength. The research of microstructure showed the reason for increased joint strength and microhardness. The microstructural study showed the reason (4 %) for higher joint strength and microhardness.  due to Significant   of SiCp close to the boundary of the dynamically recrystallized and thermo mechanically affected zone (TMAZ) was observed through rotation speed 1800 rpm. The friction stir welded ultimate tensile strength Decreases as the volume fraction increases of SiCp (18 wt.%).

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