Effect of friction stir process parameters on tensile strength of eggshell and SiC-reinforced aluminium-based composite

2020 ◽  
Vol 18 (1) ◽  
pp. 157-166
Author(s):  
Anas Islam ◽  
Shashi Prakash Dwivedi ◽  
Vijay Kumar Dwivedi
Keyword(s):  
Tensile Strength ◽  
Ball Milling ◽  
Rotational Speed ◽  
Metal Matrix ◽  
Capital Investment ◽  
Content Type ◽  
Friction Stir Process ◽  
Friction Stir ◽  
Single Entity ◽  
Strong Control

Purpose This study aims to minimize pollution and enhance the mechanical properties of SiC- reinforced aluminum- based composite by utilizing waste eggshell. Pollution is increasing at an exponential rate across the globe. Every nation is struggling to have strong control over the rise in pollution. Many countries are even successful in this regard, but only up to a certain extent; also, a lot of capital investment is required just to make arrangements for making and taking care of dedicated dump yards. An alternative approach in this regard could be using the unwanted wastes in some constructive works by recycling them. Novel strategies and dedicated cells for the research and development regarding the recycling of various kinds of wastes are continuously being developed by various nations. Design/methodology/approach This study attempts to make a hybrid composite of AA6101 alloy through the friction stir process (FSP) technique in which waste eggshells and SiC have been used as reinforcement particles. As the densities of eggshells, SiC show different values of densities to make them a single entity, they were subjected to ball milling for around 75 h. After ball milling, the reinforcement particles (eggshells and SiC) were distributed uniformly in the metal matrix (Al), and they appear as a single entity in the metal matrix composite. Findings The main objective of this study is to obtain an enhanced value of tensile strength of the final composite. Concerning this, the parameters of FSP, i.e. rotational speed and transverse speed, have been optimized through the Box–Behnken design approach. The optimized values of FSP parameters came out to be as 935.92 rpm of rotational speed and 22.48 mm/min as transverse speed value. Originality/value The results showed that the tensile strength and hardness of the composite developed at an optimum combination of FSP parameters enhanced by about 47.14 and 45.45%, respectively.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

Parametric optimization of friction stir welding process parameters of dissimilar welded joints using grey relational analysis and desirability function approach

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bhanodaya Kiran Babu Nadikudi
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Tilt Angle ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational

Purpose The main purpose of the present work is to study the multi response optimization of dissimilar friction stir welding (FSW) process parameters using Taguchi-based grey relational analysis and desirability function approach (DFA). Design/methodology/approach The welded sheets were fabricated as per Taguchi orthogonal array design. The effects of tool rotational speed, transverse speed and tool tilt angle process parameters on ultimate tensile strength and hardness were analyzed using grey relational analysis, and DFA and optimum parameters combination was determined. Findings The tensile strength and hardness values were evaluated from the welded joints. The optimum values of process parameters were estimated through grey relational analysis and DFA methods. Similar kind of optimum levels of process parameters were obtained through two optimization approaches as tool rotational speed of 1150 rpm, transverse speed of 24 mm/min and tool tilt angle of 2° are the best process parameters combination for maximizing both the tensile strength and hardness. Through these studies, it was confirmed that grey relational analysis and DFA methods can be used to find the multi response optimum values of FSW process parameters. Research limitations/implications In the present study, the FSW is performed with L9 orthogonal array design with three process parameters such as tool rotational speed, transverse speed and tilt angle and three levels. Practical implications Aluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. Originality/value Very limited work had been carried out on multi objective optimization techniques such as grey relational analysis and DFA on friction stir welded joints made with dissimilar aluminium alloys sheets.

Prediction of mechanical properties and optimization of process parameters in friction-stir-welded dissimilar aluminium alloys

2020 ◽  
Vol 17 (4) ◽  
pp. 519-526 ◽  
Author(s):  
Senthilnathan T. ◽  
Sujay Aadithya B. ◽  
Balachandar K.
Keyword(s):  
Experimental Data ◽  
Mechanical Properties ◽  
Tensile Strength ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Grey Relational

Purpose This study aims to predict the mechanical properties such as equivalent tensile strength and micro-hardness of friction-stir-welded dissimilar aluminium alloy plates AA 6063-O and AA 2014-T6, using artificial neural network (ANN). Design/methodology/approach The ANN model used for the experiment was developed through back propagation algorithm. The input parameter of the model consisted of tool rotational speed and weld-traverse speed whereas the output of the model consisted of mechanical properties (tensile strength and hardness) of the joint formed by friction-stir welding (FSW) process. The ANN was trained for 60% of the experimental data. In addition, the impact of the process parameters (tool rotational speed and weld-traverse speed) on the mechanical properties of the joint was determined by Taguchi Grey relational analysis. Findings Subsequently, testing and validation of the ANN were done using experimental data, which were not used for training the network. From the experiment, it was inferred that the outcomes of the ANN are in good agreement with the experimental data. The result of the analyses showed that the tool rotational speed has more impact than the weld-traverse speed. Originality/value The developed neural network can be used to predict the mechanical properties of the weld. Results indicate that the network prediction is similar to the experiment results. Overall regression value computed for training, validation and testing is greater than 0.9900 for both tensile strength and microhardness. In addition, the percentage error between experimental and predicted values was found to be minimal for the mechanical properties of the weldments. Therefore, it can be concluded that ANN is a potential tool for predicting the mechanical properties of the weld formed by FSW process. Similarly, the results of Taguchi Grey relational analysis can be used to optimize the process parameters of the weld process and it can be applied extensively to ascertain the most prominent factor. The results of which indicates that rotational speed of 1,270 rpm and traverse speed of 30 mm/min are to be the optimized process parameters. The result also shows that tool rotational speed has more impact on the mechanical properties of the weld than that of traverse speed.

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.%).

Prediction and optimization of mechanical properties of PA6/NBR/graphene nanocomposites fabricated by friction stir processing

2021 ◽  
pp. 009524432110200
Author(s):  
Ali Ghorbankhan ◽  
Mohammad Reza Nakhaei ◽  
Ghasem Naderi
Keyword(s):  
Tensile Strength ◽  
Impact Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Differential Scanning Calorimetric ◽  
Butadiene Rubber ◽  
Friction Stir ◽  
Graphene Nanocomposite ◽  
Graphene Nanoparticles ◽  
Input Variables

The friction stir process (FSP) method used to prepare polyamide 6 (PA6)/nitrile-butadiene rubber (NBR) nanocomposites with 1 wt% Graphene nanoparticles. Response surface methodology (RSM) and Box-Behnken design were used to study the effects of four input variables including tool rotational speed (ω), shoulder temperature (T), traverse speed (S), and the number of passes (N) on tensile strength and impact strength of PA6/NBR/Graphene nanocomposite. In order to investigate the dispersion state of Graphene and the morphology of the PA6/NBR blend in the presence of Graphene, wide x-ray patterns (WAX), scanning electron microscopy (SEM) were performed. Furthermore and differential scanning calorimetric (DSC) was used to investigate the thermal properties of PA6/NBR containing 1 wt% Graphene nanoparticles. The results confirmed that at the optimum range of input variables, PA6/NBR/Graphene nanocomposite provided good thermal stability as well as the highest tensile strength, and impact strength. This is caused by the large surface area to volume ratio of the dispersed layered Graphene in PA6/NBR blends. Under optimal conditions of the rotational speed of 1200 rpm, traverse speed of 20 mm/min, shoulder temperature of 125°C, and number pass of 3, the maximum tensile strength and impact strength are 70.4 MPa and 70.3 J/m, respectively.

Comparison of response surface methodology with artificial neural network for prediction of the tensile properties of friction stir-processed surface composites

2021 ◽  
pp. 095440892110368
Author(s):  
Ravi Butola ◽  
Ranganath M. Singari ◽  
Qasim Murtaza ◽  
Lakshay Tyagi
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Tensile Strength ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Rotational Speed ◽  
Total Elongation ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Artificial Neural

In the present work, nanoboron carbide is integrated in the aluminum matrix using friction stir processing: by varying process parameters, that is, tool pin profile, tool rotational speed and tool traverse speed, based on Taguchi L16 design of experiment. A self-assembled monolayer is successfully developed on the substrate to homogeneously and uniformly distribute the reinforcement particles. Response surface methodology and artificial neural network models are developed using ultimate tensile strength and total elongation as responses. Percentage absolute error between the experimental and predicted values of ultimate tensile strength and total elongation for the response surface methodology model is 3.537 and 2.865, respectively, and for artificial neural network is 2.788 and 2.578, respectively. For both the developed models experimental and forecasted values are in close approximation. The artificial neural network model showed slightly better predictive capacity compared to the response surface methodology model. From the scanning electron microscopy micrograph, it is evident that throughout the matrix B4C reinforcement particles are well distributed also; with increasing tool rotational speed grain size decreases up to 1200 r/min; on further increasing the tool rotational speed particles starts clustering.

Effect of Al2O3 nanoparticles on microstructure and mechanical properties of friction stir-welded dissimilar aluminum alloys AA7075-T6 and AA6061-T6

2021 ◽  
pp. 095440892110655
Author(s):  
Sumit Jain ◽  
R.S. Mishra
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Particle Dispersion ◽  
Al2o3 Nanoparticles ◽  
Tool Rotational Speed ◽  
Micro Hardness ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

In this research, a defect-free dissimilar weld joint of AA7075-T6 and AA6061-T6 reinforced with Al2O3 nanoparticles was fabricated via friction stir welding (FSW). The influence of tool rotational speed (700, 900 and 1100 rpm), traverse speed (40, 50 and 60 mm/min) with varying volume fractions of Al2O3 nanoparticles (4%, 7% and 10%) on microstructural evolution and mechanical properties were investigated. The augmentation of various mechanical properties is based on the homogeneity of particle dispersion and grains refinement in the SZ of the FSWed joint. The findings revealed that the remarkable reduction in grain size in the SZ was observed owing to the incorporation of Al2O3 nanoparticles produces the pinning effect, which prevents the growth of grain boundaries by dynamic recrystallization (DRX). The increasing volume fraction of Al2O3 nanoparticles enhanced the mechanical properties such as tensile strength, % elongation and micro-hardness. Agglomeration of particles was observed in the SZ of the FSWed joints produced at lower tool rotational speed of 700 rpm and higher traverse speed of 60 mm/min due to unusual material flow. Homogenous particle dispersion and enhanced material mixing ensue at higher rotational speed of 1100 rpm and lower traverse speed of 40 mm/min exhibit higher tensile strength and micro-hardness.

Design-of-experiments application in the friction stir welding of aluminium alloy AA 8011-h14 for structural application

2019 ◽  
Vol 16 (3) ◽  
pp. 606-622
Author(s):  
Navneet Khanna ◽  
Mahesh Bharati ◽  
Prachi Sharma ◽  
Vishvesh J. Badheka
Keyword(s):  
Tensile Strength ◽  
Aluminium Alloy ◽  
Tensile Testing ◽  
Visual Inspection ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Content Type ◽  
Taguchi Analysis ◽  
Friction Stir ◽  
Maximum Tensile Strength

Purpose The demand for aluminium alloys has been increasing in almost all the fields. In this study, the friction stir welding (FSW) of similar aluminium alloy AA 8011-h14 has been presented using three levels of tool rotational speed (n), tool tilt angle (ϴ) and tool feed (f). The purpose of this paper is to study the effect of welding parameters on various properties and time-temperature plots. Design/methodology/approach FSW was carried out using the L-9 orthogonal array of welding parameters generated using the Taguchi approach. Visual inspection and radiography testing were conducted to detect the surface and volume defects, respectively. Taguchi analysis was carried out to get optimised welding parameters for tensile testing. The microstructural analysis was carried out for the specimen possessing maximum tensile strength and the obtained grain structures were compared with the microstructure results of the base material. The peak process temperatures were noted and time-temperature plots were analysed for the varying parameters. The maximum value of hardness was recorded and analysed. Findings Visual inspection and radiography testing confirmed defect-free joints. The maximum tensile strength achieved was 84.44 MPa with 64.95 per cent efficiency. The optimised parameters obtained using Taguchi analysis for tensile testing were 1,500 rpm, 1° and 50 mm/min. Microstructure analysis for the specimen possessing maximum tensile strength revealed fine and equiaxed grains in the nugget zone. Time-temperature plots suggested the maximum temperature of 389 °C on the advancing side. A maximum hardness value of 36.4 HV was obtained in the nugget zone. Originality/value As per the knowledge of the authors, this study is the first attempt for the detailed experimental analysis on the FSW of this particular aluminium alloy AA 8011-h14.

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