Prediction of Optimum Welding parameters for Friction stir welding of Aluminium Alloy AA5083 Using Response Surface Method

AISI 304L is an austenitic Chromium-Nickel stainless steel offering the optimum combination of corrosion resistance, strength and ductility. These attributes make it a favorite for many mechanical components. The paper focuses on developing mathematical model to predict ultimate tensile strength of pulsed current micro plasma arc welded AISI 304L joints. Four factors, five level, central composite rotatable design matrix is used to optimize the number of experiments. The mathematical model has been developed by response surface method. The adequacy of the model is checked by ANOVA technique. By using the developed mathematical model, ultimate tensile strength of the joints can be predicted with 99% confidence level. Contour plots are drawn to study the interaction effect of pulsed current micro plasma arc welding parameters ultimate tensile strength of AISI 304L steel. The developed mathematical model has been optimized using Response Surface Method to maximize the ultimate tensile strength.

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Friction Stir Welding of Elements Made of Cast Aluminium Alloys

Archives of Metallurgy and Materials ◽

10.2478/amm-2014-0064 ◽

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.

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Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.789 ◽

2012 ◽

Vol 445 ◽

pp. 789-794 ◽

Cited By ~ 1

Author(s):

Vahid Moosabeiki ◽

Ghasem Azimi ◽

Mostafa Ghayoor

Keyword(s):

Friction Stir Welding ◽

Aluminium Alloy ◽

Frictional Heat ◽

Welding Parameters ◽

Zone Formation ◽

Friction Stir ◽

Tool Pin Profile ◽

Tool Shoulder ◽

Aa6061 Aluminium Alloy ◽

Tool Pin

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

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Optimization of friction stir welding parameters using multiple response surface methodology

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

10.1177/1464420715602139 ◽

2015 ◽

Vol 231 (7) ◽

pp. 571-583 ◽

Cited By ~ 5

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.

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Dynamic Recrystallization Mechanisms on Spot Welding of 6008 Aluminium Alloy to Steel by Friction Stir Welding

Materials Science Forum ◽

10.4028/www.scientific.net/msf.558-559.477 ◽

2007 ◽

Vol 558-559 ◽

pp. 477-483 ◽

Cited By ~ 3

Author(s):

Sandrine Bozzi ◽

Anne Laure Etter ◽

Thierry Baudin ◽

A. Robineau ◽

Jean Claude Goussain

Keyword(s):

Friction Stir Welding ◽

Dynamic Recrystallization ◽

Aluminium Alloy ◽

Dwell Time ◽

Tensile Tests ◽

Mechanical Tests ◽

Welding Parameters ◽

Electron Backscattered Diffraction ◽

Friction Stir ◽

Continuous Dynamic Recrystallization

At the prospect of a lightening of the automobile structures, welded spots have been realized on a stacking of two sheets (a 6008 aluminium alloy on steel) by Friction Stir Welding (FSW). Different process parameters have been tested but only the influence of the dwell time will be described in the present paper. The dwell time corresponds to the time during which the probe stays in rotation at its bottom location before extracting. A study of the microstructures and the crystallographic textures associated to mechanical tests (shear and tensile tests) allowed to determine the best set of welding parameters. The recrystallized area around the welding spot has been characterized by Electron BackScattered Diffraction (EBSD). The aim of the present work is to identify the recrystallization mechanisms which occur during welding, and to understand the influence of the dwell time on the recrystallized area. A mechanism of continuous dynamic recrystallization has been identified since misorientation of sub-boundary increases close to the weld and this for all the dwell times tested. Elsewhere, it has been found that the increase of the dwell time induces a larger recrystallized zone.

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