Optimization of microstructural and mechanical properties of brass wire produced by friction stir extrusion using Taguchi method

2021 ◽  
pp. 146442072110329
Author(s):  
Mostafa Akbari ◽  
Parviz Asadi
Keyword(s):  
Grain Size ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Wire Diameter ◽  
Dominant Factor ◽  
Friction Stir ◽  
Optimum Parameters ◽  
Ultimate Pressure ◽  
The Wire

Friction stir back extrusion is used to produce brass wires from its chips, and then the process parameters are optimized using Taguchi L9 orthogonal design of experiments. The rotational speed, traverse speed, and the produced wire diameter are the parameters taken into consideration. The optimum process parameters are determined with respect to grain size, microhardness, and ultimate pressure strength of the produced samples. The predicted optimum values for output parameters are confirmed by conducting the confirmation test using optimum parameters. Analysis of variance shows that the rotational speed is the most dominant factor in determining the grain size and microhardness of the produced wires, and the tool traverse speed and the wire diameter are the second and the third effective parameters. However, in terms of the produced wires ultimate pressure strength, the traverse speed is the most dominant factor rather than the rotational speed. The optimum values for the rotational speed, the traverse speed, and the wire diameter are 500 r/min, 31.5 mm/min, and 6 mm, respectively, and the produced wire, by these optimum parameters, presents 14.17 µm, 127.1 HV, and 904.7 MPa for the grain size, the microhardness, and the ultimate pressure strength, respectively.

Influence of Process Parameters on Microstructure of Friction Stir Processed Mg AZ31 Alloy

2017 ◽  
pp. 1293-1305
Author(s):  
G. Venkateswarlu ◽  
M.J. Davidson ◽  
G.R.N. Tagore ◽  
P. Sammaiah
Keyword(s):  
Plastic Deformation ◽  
Grain Refinement ◽  
Process Parameters ◽  
Tilt Angle ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Homogeneous Microstructure ◽  
Friction Stir ◽  
Tool Tilt Angle

Friction stir processing (FSP) has been developed on the principles of friction stir welding (FSW) as an effective and efficien new method for grain refinement and microstructural modification, providing intense plastic deformation as well as higher strain rates than other conventional severe plastic deformation methods. FSP produces an equiaxed homogeneous microstructure consisting of fine grains, resulting in the enhancement of the properties of the material at room temperature. The objective of the present paper is to examine the influence of friction stir processing (FSP) parameters namely tool rotational speed (RS), tool traverse speed (TS) and tool tilt angle (TA) on the microstructures of friction stir processed AZ31B-O magnesium alloy. This investigation has focused on the microstructural changes occurred in the dynamically recrystallised nugget zone/ stir zone and the thermo mechanically affected zone during FSP. The results presented in this work indicate that all the three FSP process parameters have a significant effect on the resulting microstructure and also found that the rotational speed has greatly influenced the homogenization of the material. The grain refinement is higher at intermediate rotational speed (1150 rpm), traverse speed (32 mm / min and tilt angle (10). It is established that FSP can be a good grain refinement method for improving the properties of the material.

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.

scholarly journals Research the Effect of Process Parameters on Friction Stir Welded AA6063-ETP Copper joint using Taguchi Technique

2019 ◽  
Vol 8 (2S11) ◽  
pp. 884-888
Keyword(s):  
Thermal Conductivity ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Copper Plate ◽  
Heat Sinks ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Alloy Plate ◽  
Friction Stir

Aluminium and copper, or their combination finds application in heat sinks because of their excellent thermal conductivity. In the present study, Al–6063 and ETP copper were lap welded using friction stir welding wherein the aluminum alloy plate was placed on top of the copper plate. The optimum process parameters were found using Taguchi L9 orthogonal array. The process parameters namely tool rotational speed, tool traverse speed and thickness of zinc inter-filler material were considered. The optimal process parameters were ascertained with respect to the thermal conductivity of weld. The predicted optimum value of thermal conductivity was verified by conducting the confirmation run using the optimal parameters. Analysis of variance depicted that all the three process parameters were significant, wherein the tool rotational speed and the tool traverse speed were the most dominant factors contributing to thermal conductivity.

Influence of Process Parameters on Microstructure of Friction Stir Processed Mg AZ31 Alloy

2014 ◽  
Vol 2 (1) ◽  
pp. 47-58
Author(s):  
G. Venkateswarlu ◽  
M.J. Davidson ◽  
G.R.N. Tagore ◽  
P. Sammaiah
Keyword(s):  
Plastic Deformation ◽  
Grain Refinement ◽  
Process Parameters ◽  
Tilt Angle ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Homogeneous Microstructure ◽  
Influence Of Process Parameters ◽  
Friction Stir

Friction stir processing (FSP) has been developed on the principles of friction stir welding (FSW) as an effective and efficien new method for grain refinement and microstructural modification, providing intense plastic deformation as well as higher strain rates than other conventional severe plastic deformation methods. FSP produces an equiaxed homogeneous microstructure consisting of fine grains, resulting in the enhancement of the properties of the material at room temperature. The objective of the present paper is to examine the influence of friction stir processing (FSP) parameters namely tool rotational speed (RS), tool traverse speed (TS) and tool tilt angle (TA) on the microstructures of friction stir processed AZ31B-O magnesium alloy. This investigation has focused on the microstructural changes occurred in the dynamically recrystallised nugget zone/ stir zone and the thermo mechanically affected zone during FSP. The results presented in this work indicate that all the three FSP process parameters have a significant effect on the resulting microstructure and also found that the rotational speed has greatly influenced the homogenization of the material. The grain refinement is higher at intermediate rotational speed (1150 rpm), traverse speed (32 mm / min and tilt angle (10). It is established that FSP can be a good grain refinement method for improving the properties of the material.

scholarly journals Optimization of Process Parameters on Friction Stir Welding of AA 6082-T6 Butt Joints Using Taguchi Method

2020 ◽  
Vol 22 (4) ◽  
pp. 1371-1380
Author(s):  
Mustapha Arab ◽  
Mokhtar Zemri
Keyword(s):  
Friction Stir Welding ◽  
Taguchi Method ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optimum Process ◽  
Friction Stir ◽  
Optimum Parameters ◽  
Optimization Of Process Parameters ◽  
Two Factors

AbstractFriction Stir Welding (FSW) was carried out on Aluminum Alloy 6082-T6 plates with dimensions of 200 × 70 × 2 mm. Design of Experiment (DOE) was applied to determine the most important factors which influence the Ultimate Tensile Strength (UTS) and Hardness (HV) of AA 6082-T6 joints produced by Friction Stir Welding (FSW). Effect of two factors which include tool rotational speed and welding speed on (UTS, HV) were investigated by Taguchi method using L9 orthogonal array to find the optimum process parameters. An analysis of variance (ANOVA) was carried out to determine which of the selected factors are more significant on both of responses, the optimum parameters for the higher UTS it found by using a rotational speed of 1400 rpm and 125 mm/min for the welding speed, also 1400 rpm and 160 mm/min to maximize Hardness (HV).

scholarly journals Effect of Process Parameters on Defect Features and Mechanical Performance of Friction Stir Lap Welded AA6063 and ETP Copper Joints

2019 ◽  
Vol 8 (2S11) ◽  
pp. 879-883
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Defect Formation ◽  
Mechanical Performance ◽  
Traverse Speed ◽  
Weld Strength ◽  
Dissimilar Metals ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
The Difference

The effect of process parameters such as tool rotational speed and tool traverse speed on mechanical properties of AA-6063 and ETP Cu lap joint is investigated. At present, Friction Stir Welding is being employed to join dissimilar metals. However, the difference in the physical properties of the base metals makes it difficult to join these metals. The present study investigates the effect of using a compatible intermediate layer on weld strength. Different joint defects and their effect on joint strength has been discussed. The experiments were conducted with tool rotational speed of 800, 1000 and 1200 rpm each and with tool traverse speeds of 10, 15 and 20 mm/min. The dissimilar metals are successfully lap welded with fair tensile strength. The effect of process parameters on weld strength and defect formation is discussed

scholarly journals Influence of Friction Stir Processing Parameters on Mg ZE 41-SiC Surface Composite

2019 ◽  
Vol 8 (2) ◽  
pp. 6058-6061
Keyword(s):  
Process Parameters ◽  
Tilt Angle ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Nano Particles ◽  
Micro Hardness ◽  
Friction Stir ◽  
Surface Composite ◽  
Tool Tilt Angle

In this study, the influence of friction stir processing process parameters (FSP), such as tool rotational speed, tool traverse speed, and the tool tilt angle on the mechanical properties of Sic reinforced surface magnesium rare earth ZE41 alloy composite was studied. The process was carried at tool rotational speeds of 710, 900, 1120, 1600, 1400 and 1800 rpm, tool traverse speeds of 16, 25, 40 and 63 mm/min and tool tilt angle of degree 1. Nano-particles of SiC (40 microns) were used as reinforcements to produce a composite surface. The grain refinement of the processed specimens was analyzed using scanning electron microscope. It is observed from the results that FSP process parameters influenced the surface composite area, SiC particles distribution and micro hardness of the composite. The outcomes indicated that the higher micro hardness was obtained at rotational speed of 1100 RPM, traverse speed 40mm/min and tilt angle 10 .

Investigation on the best process criteria for lap joint friction stir welding of AA1100 aluminum alloy via Taguchi technique and ANOVA

2016 ◽  
Vol 231 (2) ◽  
pp. 329-342 ◽  
Author(s):  
Abolfazl Khalkhali ◽  
Morteza Sarmadi ◽  
Ehsan Sarikhani
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Analysis Of Variance ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Taguchi Technique ◽  
Lap Joint ◽  
Joint Friction ◽  
Friction Stir

Friction stir welding is a novel joining process extensively used for welding of aluminum alloys. It is widely known that the process parameters involved in friction stir welding play a pivotal role in determining the final characteristics and microstructure of the joint. However, it is still unclear that what combination of process parameter values will lead to the optimum joint characteristics. Taguchi technique is a handy and efficient method that has been widely used for performing optimization in manufacturing engineering. In this paper, lap joint friction stir welding was performed on AA1100 and the process parameters were optimized using Taguchi L16 orthogonal design of experiments. Unlike previous studies on optimization of friction stir welding process in aluminum alloys, a more comprehensive approach has been taken towards the number of input and output parameters of the process. Process parameters considered in this study were tool rotational speed, tool traverse speed, tool tilt angle, and tool pin shape. The optimum design was obtained with reference to output parameters including hardness and grain size in the weld center zone, maximum working temperature, joint tensile strength, and elongation as well as the vertical and horizontal forces on the tool during the process. Analysis of variance was additionally performed to evaluate the significance of each design parameter on output parameters. Results gained from analysis of variance indicated that rotational speed and traverse speed were the most critical parameters in determining the weld mechanical properties as well as quality of the weld microstructure. Finally, to validate predicted optimum values based on Taguchi technique, confirmation tests were conducted, where an excellent agreement was observed between the predicted and experimental values, showing accuracy of the employed method and obtained results.

Microstructural Refinement of Pure Copper by Friction Stir Processing

2013 ◽  
Vol 787 ◽  
pp. 256-261 ◽  
Author(s):  
Salar Salahi ◽  
Vahid Rezazadeh ◽  
Ali Sharbatzadeh ◽  
Atabak Iranizad ◽  
Hamed Bouzary
Keyword(s):  
Grain Size ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Frictional Heating ◽  
Pure Copper ◽  
Traverse Speed ◽  
Work Piece ◽  
Process Conditions ◽  
Nugget Zone ◽  
Friction Stir

Recently friction stir processing (FSP) was developed as a generic implement for microstructural modification based on the principles of FSW using a rotating tool inserted in a monolithic work piece which provides frictional heating and mechanical mixing. In this paper, the microstructural evolution characteristics of nugget zone were investigated during friction stir processing (FSP) of pure copper. Pure copper plates were friction stir processed to the depth of 3.4 mm at different process conditions by varying the traverse speed from 30 to 120 mm/min at rotation speeds of 400 and 600 rpm..Defects were observed in rotational speed of 400 rpm. Grain size of NZ depended significantly on plastic deformation and heat input value. By increasing traverse speed at constant rotational speed of 600 rpm grain size of the nugget zone decreased and the hardness increased. Ultimate tensile strength increased with decrease in grain size. FSP was found as an effective method to develop fine-grained microstructure in copper plates.

Effect of Processing Parameters on Thermo-Mechanically Affected Zone of Friction Stir Processed AZ91 Magnesium Alloy

2010 ◽  
Author(s):  
M. Taherishargh ◽  
N. Parvin ◽  
P. Asadi
Keyword(s):  
Grain Size ◽  
Magnesium Alloy ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Processing Parameters ◽  
The Other ◽  
Az91 Magnesium Alloy ◽  
Friction Stir ◽  
Az91 Magnesium

AZ91 Magnesium alloy was subjected to friction stir processing (FSP). The microstructural analyses of the friction stir processed (FSPed) specimens were carried out and the effects of pass number, rotational speed, and traverse speed upon thermo-mechanically affected zone (TMAZ) were investigated. The TMAZ is consisted of a region with highly elongated grains and a partially recrystalized zone. Decreasing the rotational speed and increasing the traverse speed increased the thickness of recrystallized zone; while, the thickness of the other zone decreased. On the other hand, it lessened the gradient of the grain size from the stir zone (SZ) to the base metal. Applying several FSP passes, lead to more homogeneous TMAZ structure with the finer grain size.

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