Analysis of process parameters effects on underwater friction stir welding of aluminum alloy 6082-T6

2018 ◽  
Vol 233 (6) ◽  
pp. 1700-1710 ◽  
Author(s):  
Mohd Atif Wahid ◽  
Zahid A Khan ◽  
Arshad Noor Siddiquee ◽  
Rohit Shandley ◽  
Nidhi Sharma
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Underwater Friction Stir Welding ◽  
Optimal Setting

In friction stir welding of heat treatable aluminum alloys, the thermal cycles developed during the joining process result in softening of the joints which adversely affect their mechanical properties. Underwater friction stir welding can be a process of choice to overcome this problem due to low peak temperature and short dwell time involved during the process. Consequently, this article presents a study pertaining to the underwater friction stir welding of aluminum alloy 6082-T6 with an aim to develop a mathematical model to optimize the underwater friction stir welding process parameters for obtaining maximum tensile strength. The results of the study reveal that the tool shoulder diameter (d), tool rotational speed (ω), welding speed (v), and second-order term of rotational speed, that is, ω2, significantly affect the tensile strength of the joint. The maximum tensile strength of 241 MPa which is indeed 79% of the base metal strength and 10.7% higher than that of conventional (air) friction stir welding joint was achieved at an optimal setting of the underwater friction stir welding parameters, that is, tool rotational speed of 900 r/min, the welding speed of 80 mm/min, and a tool shoulder of 17 mm. The article also presents the results of temperature variation, the macrostructural and microstructural investigations, microhardness, and fractography of the joint obtained at the optimal setting for underwater friction stir welded (UFSWed) joint.

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.

Effect of Friction Stir Welding Process Parameters on Temperature Profile and Tensile Strength of Dissimilar Aluminum Alloys

2015 ◽  
Vol 813-814 ◽  
pp. 425-430
Author(s):  
Saurabh Kumar Gupta ◽  
K.N. Pandey ◽  
Rajneesh Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Temperature Profile ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Peak Temperature ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

The aim of this research is to study the effect of Friction Stir Welding (FSW) process parameters such as tool rotational speed and welding speed on temperature distribution and tensile strength of dissimilar AA5083-O and AA6063-T6 joint welded by FSW. Peak temperature at retreating side was observed lower as compared to advancing side for each experiment. Peak temperature decreases with decreasing the tool rotational speed but vice versa with welding speed. ANOVA indicated that the temperature profile was strongly dependent on the tool rotation speed than the welding speed and it also showed that welding speed is the main process parameter that has highest effect on tensile strength of welded joint.

Multi-Performance Optimization in Friction Stir Welding of Aluminum Alloy Using Response Surface Methodology

2018 ◽  
pp. 240-263
Author(s):  
Rajat Gupta ◽  
Kamal Kumar ◽  
Neeraj Sharma
Keyword(s):  
Response Surface Methodology ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Response Surface ◽  
Process Parameters ◽  
Performance Optimization ◽  
Desirability Function ◽  
High Carbon Steel ◽  
Friction Stir ◽  
Tool Shoulder

This chapter presents the friction stir welding (FSW) of aluminum alloy AA-5083-O using vertical milling machine. In present FSW experimentation, effects of different process parameter namely tool rotation speed, welding speed, tool geometry, and tool shoulder diameter have been determined on welding quality of two pieces of AA-5083-O using response surface methodology (RSM). The optimal sets of process parameters have been determined for weld quality characteristics namely tensile strength (UTS) and percentage elongation (%EL). In present experimentations, a specially designed tool made of high carbon steel with different shoulder diameters (15mm, 17.5mm, and 20 mm) having constant pin length (6 mm) were used for FSW of two pieces of aluminum alloy. The ANOVA and pooled ANOVA were used to study the effect of FSW parameters on UTS and %EL. Multi response optimization has been carried out using desirability function in conjunction with RSM to obtain the optimal setting of process parameters for higher UTS and lower %EL.

Optimization of Welding Process Parameters in Novel Friction Stir Welding of Polyamide 66 Joints

2019 ◽  
Vol 969 ◽  
pp. 828-833 ◽  
Author(s):  
R. Nandhini ◽  
R. Dinesh Kumar ◽  
S. Muthukumaran ◽  
S. Kumaran
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Polyamide 66 ◽  
Friction Stir ◽  
Response Characteristics ◽  
Tool Shoulder ◽  
Stereo Microscope ◽  
Friction Plate

The friction stir welding of polyamide 66 with a specially modified tool is studied. A variation of the conventional friction stir welding is investigated by incorporating a friction plate for the purpose of heating the polymer in the course of welding process through the tool shoulder. This in turn, improves the efficiency of the weld. The association of the welding process parameters and the weld performance has been investigated by the grey relational analysis with multi response characteristics like weld tensile strength, percent elongation and hardness. Macrostructure of the weld joint cross section has been explored by Stereo microscope. The maximum weld tensile strength of 63 MPa and a Shore hardness of 60 D at the weld nugget are obtained. The hardness profiles of the welded samples have been analyzed in this investigation.

scholarly journals Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1480
Author(s):  
Assefa Asmare ◽  
Raheem Al-Sabur ◽  
Eyob Messele
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Weight Ratio ◽  
Welding Process ◽  
Quality Criteria ◽  
Alloy Sheet ◽  
Friction Stir ◽  
Weld Joints

The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

Process Parameters Optimization of Friction Stir Welding in Aluminium Alloy 6063-T6 by Taguchi Method

2017 ◽  
Vol 867 ◽  
pp. 97-104 ◽  
Author(s):  
T. Ganapathy ◽  
K. Lenin ◽  
K. Pannerselvam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Taguchi Method ◽  
Axial Force ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Process Parameter ◽  
Main Process ◽  
Friction Stir

This paper deals with the effective application of friction stir welding similar to butt joining technique.AL6063 T-6 alloys prepared in 125x 100 x 7mm thickness plate and FSW tool setup were H13 of diameter 25mm rotary tool with straight cylindrical pin profile. The maximum strength was considered for selection of combined process parameter. The process parameters were optimized using Taguchi method. The Rotational speed, welding speed, and axial speed are the main process parameter which taken into our consideration. The optimum process parameters are determined with reference to tensile strength of the joint. From the experiments, it was found the effects of welding parameter are the axial force is highest substantial parameter to determining the tensile strength of the joint. The paper which revealed the optimal values of process parameter are to acquire a maximum tensile strength of friction stir welded AL6063-T6 plates is 101.6Mpa with the combination level of rotational speed, welding speed and axial force are found to be 1100 RPM, 60 mm/min and 12.5 KN. validation test was carried out and results were nearer to the optimized results confirmed by the optimum results.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
Anganan K ◽  
Narendran RJ ◽  
Naveen Prabhu N ◽  
Rahul Varma R ◽  
Sivasubramaniyam R
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

Optimization of process parameters for friction stir welding of joining A6061 and A6082 alloys by Taguchi method

2012 ◽  
Vol 227 (6) ◽  
pp. 1150-1163 ◽  
Author(s):  
Sanjay Kumar ◽  
Sudhir Kumar ◽  
Ajay Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Experimental Tests ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Optimization Of Process Parameters ◽  
Tool Pin

The friction stir welding is a pioneering solid-state metal joining technique for producing high-quality joints in materials. In this article, Taguchi approach is applied to analyze the optimal process parameters for optimum tensile strength and hardness of welded dissimilar A6061 and A6082 alloys. An orthogonal array of L9 is implemented and the analysis of variance is employed to investigate the importance of parameters on responses. The experimental tests, conducted according to combination of rotational speed, tool tilt and types of tool pin profile parameters. The results indicate that the rotational speed is most significant process parameter that has the highest influence on tensile strength and hardness, followed by tool pin profile and tool tilt. The optimum results verified by conducting confirmation experiments. The predicted optimal value of tensile strength and hardness of dissimilar joints produced by friction stir welding are 267.74 MPa and 80.55 HRB, respectively.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
K. Anganan ◽  
R.J . Narendran ◽  
N Naveen Prabhu ◽  
R Rahul Varma ◽  
R Sivasubramaniyam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

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