Study of optimum welding performance in friction stir welding of dissimilar Mg alloys using integrated RSM-TLBO algorithm

2021 ◽  
pp. 095440892110581
Author(s):  
Umesh Kumar Singh ◽  
Avanish Kumar Dubey
Keyword(s):  
Surface Roughness ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Optimization Algorithm ◽  
Welding Speed ◽  
Rotational Speed ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Teaching Learning Based Optimization ◽  
Teaching Learning

Lightweight with excellent strength of magnesium alloys has attracted its use in transportation industries but difficulty in fusion welding of magnesium alloys restricts its application. The present research investigates solid state friction stir welding of dissimilar AZ31-AZ91 magnesium alloys with aim to achieve optimum quality welds. Surface roughness, microstructure and mechanical properties of these joints have been investigated at different tool rotational speed, welding speed and tool shoulder diameter. Maximum joint strength obtained is 89.71% (as compare to AZ31) which is more than the previously reported joint strengths of dissimilar magnesium alloys. Further, mathematical relations for responses have been developed and utilised for multi-objective optimization using teaching-learning-based optimization algorithm. Eventually, teaching-learning-based optimization algorithm results suggest that the optimum value of surface roughness (3.3925 µm), grain size (12.6869 µm), tensile strength (237.9621 MPa), microhardness (69.3652 Hv) and flexural strength (333.2285 MPa) can be achieved at 921 rpm rotational speed, 30 mm/min welding speed and 15 mm shoulder diameter with overall improvement in multiple responses.

scholarly journals Parametric optimization of friction stir welding of Al-Mg-Si alloy: A case study

2021 ◽  
pp. 7-7
Author(s):  
Nasir Khan ◽  
Sandeep Rathee ◽  
Manu Srivastav
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Automobile Construction ◽  
Input Variables

Al-Mg-Si alloys have wide applications in industries such as aerospace, marine, automobile, construction. In this work, newly developed friction stir welding (FSW) was utilized for joining of AA6082-T6 alloy. The effect of major FSW process variables like rotational speed, traverse speed, and shoulder diameter of tool is studied over microstructural and mechanical characteristics of friction stir welded (FSWed) joints. Experimental design was done using Taguchi method (L9 orthogonal array). Three factors viz. rotational speed, welding speed, and diameter of tool shoulder were taken at three levels each. Mathematical modelling was developed in order to optimize the tensile strength of weld joints. Analysis of variance (ANOVA) was utilized to determine the percentage contribution of input variables. The results of present study exhibits that shoulder diameter, rotation, and welding speed of tool significantly affect the mechanical strength of FSWed joints.

Multi-response optimization of friction stir welding process of dissimilar AA3003-H12 and C12200-H01 alloys using full factorial method

2021 ◽  
pp. 095440892110082
Author(s):  
Gurunath V Shinde ◽  
Rachayya R Arakerimath
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Microstructural Analysis ◽  
Research Work ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Tool Pin ◽  
Full Factorial

In current research work, an attempt has been made to join dissimilar metals by employing friction stir welding (FSW), i.e., AA3003-H12 (aluminium alloy) and C12200-H01 (copper alloy). The experiments are designed as per full factorial design at different process parameters, namely tool pin profiles, rotational speed, welding speed, and shoulder diameter while the ultimate tensile strength (UTS), yield strength (YS), and percentage elongation (% E) are considered as a performance parameter. Moreover, a statistical tool, i.e., analysis of variance (ANOVA) is also utilized to check the adequacy of the results. It is observed that the higher UTS, % E and YS are obtained by employing a taper pin profile tool at a rotational speed of 1800 rpm, a welding speed of 16 mm/min, and a shoulder diameter of 22.5 mm. The ANOVA results showed that the rotational speed is the most significant factor for current research work. In addition, a scanning electron microscope is utilized for microstructural analysis of welded joints. It is witnessed that the minimum grain size, i.e., 4 microns, is obtained for highest strength specimen and the maximum grain size is obtained for the lowest strength specimen i.e., 31 microns. Besides this, the swirling of cu particle is also observed from advancing side (AS) to the retreating side (RS). Moreover, energy-dispersive X-ray spectroscopy (EDS) indicates the formation of intermetallic compounds i.e. Al2Cu, Al9Cu4 at nugget zone (NZ). The hardness is found to be higher at NZ due to the presence of Al-Cu intermetallic.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

Mechanical Property of Friction Stir Welded Retardant Magnesium Alloy Joint

2011 ◽  
Vol 295-297 ◽  
pp. 1929-1932
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Xin Zhang ◽  
Ke Ke Zhang
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Welding Speed ◽  
Rotational Speed ◽  
Maximum Strength ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

In order to obtain better understanding of the friction stir weldability of the magnesium alloy and provide some foundational information for improving mechanical properties of retardant magnesium alloy joints. A retardant magnesium alloy was weld using the method of friction stir welding. The influence of welding parameters on the strength of the joint was investigated. The maximum strength of 230 MPa was obtained from the joint welded at the tool rotational speed of 1000 r/min and welding speed of 750 mm/min.

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 Study on Friction Stir Welding of Dissimilar Al 6061 to Trip 780/800 Steel

2014 ◽  
Author(s):  
Xun Liu ◽  
Shuhuai Lan ◽  
Jun Ni
Keyword(s):  
Friction Stir Welding ◽  
Cross Sections ◽  
Welding Speed ◽  
Rotational Speed ◽  
Maximum Temperature ◽  
Friction Stir ◽  
Al 6061 ◽  
Tool Axis ◽  
Edge Temperature ◽  
Welding Force

Friction stir welding (FSW) of dissimilar Al 6061 and TRIP 780/800 steel has been performed under different process parameters, including tool rotational speed, welding speed as well as the relative position of the tool axis to the abutting edge. Temperature and mechanical welding force was recorded during the process. Welding speed has an insignificant effect on either the maximum temperature or welding force. However, it can directly change the length of high temperature duration, which will accordingly influence temperature distribution in the weld and the microstructure. Higher rotational speed can effectively elevate weld temperature through greater amount of heat input. Metallurgical observations on weld cross sections perpendicular to the joint line was performed using both optical and scanning electron microscope. Microstructure evolution was analyzed and related to the force and temperature measurement results during the FSW process.

scholarly journals Microstructural developments and mechanical properties of friction stir welding of AZ91D magnesium alloy plates

10.30544/221 ◽  
2017 ◽  
Vol 23 (2) ◽  
pp. 119-130 ◽  
Author(s):  
Nagabhushan Kumar Kadigithala ◽  
Vanitha C
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Grain Structure ◽  
Friction Stir ◽  
Transverse Tensile ◽  
Α Phase ◽  
Die Cast ◽  
Constant Strength ◽  
Fusion Weld

Friction stir welding (FSW) is an efficient technique which can be used particularly for magnesium and aluminum alloys that are difficult to fusion weld. In this work AZ91D Mg alloy plates 3mm thick were friction stir welded at different process variables such as rotational speed and welding speed. The range of rotational speeds varied from 1025 to 1525 rpm, and the welding speed varied from 25 to 75 mm/min. Good quality welds were obtained under 1025 rpm of rotational speed with the welding speeds range from 25 to 75 mm/min. The microstructure of the AZ91D alloy consists of primary α-phase, eutectic α-phase and eutectic β (Mg17Al12) phase in the received condition (gravity die cast). The original dendrite grain structure completely disappeared and was transformed to fine equiaxed grains in stir zone (SZ). It was observed that there was a slight increase in hardness in SZ, because of fine recrystallized grain structure. The transverse tensile test results of weld specimens indicated constant strength irrespective of traveling speed. Fractrographic analysis of the friction stir welded specimens showed the brittle failure.

scholarly journals Thermal Cycles and Deformation Characters During High-Speed Micro Friction Stir Welding Process of AA7075-T6 Sheets

Metals ◽  
2019 ◽  
Vol 9 (11) ◽  
pp. 1236
Author(s):  
Ni ◽  
Mao ◽  
Qin ◽  
Xiao ◽  
Fu
Keyword(s):  
Elevated Temperature ◽  
Friction Stir Welding ◽  
Exposure Time ◽  
Welding Speed ◽  
Rotational Speed ◽  
High Speed ◽  
Peak Temperature ◽  
Friction Stir ◽  
Backing Plate ◽  
Temperature Exposure

Thermal cycles and deformations during high-speed micro friction stir welding (μFSW) under different welding conditions were studied by experimental methods. The results show that the peak temperature and elevated-temperature exposure time (t150) increased with the increasing of rotational speed and decreased with the increasing of welding speed. Increasing rotational speed or welding speed led to an increase in both heating and cooling rates. The joint fabricated by the pinless tool experienced a lower peak temperature, a shorter elevated-temperature exposure time, and a larger temperature gradient than that by the pin tool. The welded sheet presented an anti-saddle deformation character, with convex bending in a longitudinal direction and concave angular bending in a transverse direction. In comparison to the pin tool, the longitudinal maximum bending deformation, Zmax, of the joint fabricated by the pinless tool was reduced by 12.35%, and the transverse angular deformation, α, was reduced by 6.67%. In comparison to the steel backing plate, the Zmax of the joint produced using a copper backing plate was reduced by 40.66%, but the α was increased by 53.27%.

Experimental investigation and optimization of mechanical properties on combination of higher and lower strength of aluminum alloys

2021 ◽  
pp. 095440892110606
Author(s):  
C Ganesan ◽  
K Manonmani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Axial Load ◽  
Welding Process ◽  
Process Parameter ◽  
Nugget Zone ◽  
Friction Stir ◽  
Tool Pin

Friction stir welding is a high potential technology for joining similar and dissimilar aluminum materials, utilized extensively in aerospace and automotive industrial applications to eradicate the problems like hot cracking, porosity, element loss, etc. due to the fusion welding process. This Research addresses the joining of two dissimilar materials of AA 5754 – H32 and AA 8090T6511 – Al-Li and their mechanical properties analysis with the effects of friction stir welding process parameters like tool rotational speed, welding speed and axial load on weld nugget zone formation quality. The significant roles of different tool pin profiles are also emphasized. A mathematical modeling equation was formed by using regression analysis to optimize the process parameter and found the best tool pin profile for defect-free weld nugget zone and higher tensile and hardness properties. This research also portrays the contribution of various pin profiles and each process parameter on the ultimate tensile strength by response surface methodology. The results indicate that the defect-free weld joints are observed with 1800 r/min of rotational speed, welding speed of 15 mm min−1 and 8.5 kN of axial load with hexagonal pin profile.

Effect of Shoulder Diameter on the Resulting Interfacial Regions of Friction Stir Welds between Aluminium and Copper

2011 ◽  
Vol 299-300 ◽  
pp. 1146-1150
Author(s):  
Esther Titilayo Akinlabi ◽  
Stephen Akinlabi
Keyword(s):  
Friction Stir Welding ◽  
Feed Rate ◽  
Rotational Speed ◽  
Force Feedback ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Stir Zone ◽  
Vertical Force ◽  
Friction Stir ◽  
Shoulder Diameter

This paper reports the effect of shoulder diameter on the resulting interfacial regions of joints between aluminium and copper produced by the friction stir welding process. The welds were produced using three shoulder diameter tools, viz; 15, 18 and 25 mm. This paper focuses on welds produced at a constant rotational speed of 600 rpm and feed rate of 50 mm/min varying the shoulder diameters. Analysis of the force feedback revealed that the advancing force, the downward vertical force and the torque increases as the shoulder diameter increases. Microstructural characterization was conducted on the joint interfaces and it was observed that the widths of the interfacial regions comprising of the Stir Zone and the Thermo – Mechanically Affected Zone (TMAZ) increases as the shoulder size increases.

Sign in / Sign up

Export Citation Format

Share Document