scholarly journals Parametric Optimization of Mechanical Properties via FSW on AA5052 Using Taguchi Based Grey Relational Analysis

2021 ◽  
Vol 13 (2) ◽  
pp. 21-30
Author(s):  
C. CHANAKYAN ◽  
S. SIVASANKAR ◽  
M. MEIGNANAMOORTHY ◽  
S. V. ALAGARSAMY
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational ◽  
Tool Pin

The Friction stir processing benefits of aluminium composites contain advanced exploration in the region of aluminium alloy Friction Stir Welding - FSW. The modern advancements in Friction Stir Welding are concentrated on the optimization of welding parameters for multi response attributes. The investigations were carried out with the tool pin profiles, tool rotational speed and traverse speed as predictable process parameters for multi response optimization in Friction Stir Welding of 5052 aluminium alloy. GRG (grey relational grade) was obtained by the grey relational analysis of the friction stir welding process through different qualities, particularly, UTS-ultimate tensile strength and micro hardness. The significant process variables on GRG and most substantial parameters traverse speed and tool pin profiles are examined by ANOVA. Excluding tool rotational speed, tool pin profiles and traverse speed were likewise observed to be significant. To approve the investigation, verification of tests was completed at optimal parameters arrangement and predicted outcomes were observed to be in great concurrence with test values.

scholarly journals Effects of process parameters on mechanical and metallurgical properties of AA5083 weld bead and optimization by using Taguchi based grey relational analysis and ANOVA of submerged friction stir welding.

2021 ◽  
Author(s):  
Laxmanaraju salavaravu ◽  
◽  
Lingaraju Dumpala ◽  
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Weld Zone ◽  
Process Conditions ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational

Friction stir welding (FSW) can be made to improve the mechanical properties in the weld zone. This article aims to obtain the optimum FSW process parameters used for two plates of AA5083 welded joints. The significant factors in the FSW process are tool rotational speed(TRS), tool transverse speed(TTS), and the weld process conditions are Submerged FSW and Normal FSW. For doing the investigation, the Taguchi method L18 orthogonal array design of experimentation is utilized. Using the Grey Relational Analysis(GRA) to calculate the grey relation grade, the response parameters are tensile strength, microhardness, and surface roughness. The Optimum process parameters contain been recognized, and ANOVA controls the significant contribution of process parameters. The optimal FSW process parameters are used to maximize the FSW joint strength. It is identified in the condition of Submerged FSW, high tool rotational speed, and low TTS.

Friction Stir Welding of Aluminum and Magnesium Alloys—Experimental Investigation and Optimization Using Hybrid Grey Relational Analysis and Principal Component Analysis

2018 ◽  
Vol 15 (2) ◽  
pp. 509-520
Author(s):  
D. Raguraman ◽  
D. Muruganandam ◽  
L. A. Kumaraswamidhas
Keyword(s):  
Principal Component Analysis ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Axial Load ◽  
Principal Component ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational

Friction stir welding of dissimilar materials is investigated experimentally in this work and optimization is performed by applying a hybrid Taguchi-Grey relational analysis-Principal component analysis to maximize the tensile strength and hardness of the weld bead. Two dissimilar metals AA6061 and AZ61 is friction stir welded and considered for the experimentation. Experimental matrix is designed using Taguchi's Design of Experiment (DOE). Optimum inputs rotational speed, axial load and transverse speed is obtained by applying the hybrid optimization technique. Statistical analysis of Multi Response Performance Index (MRPI) through Analysis of Variance (ANOVA) shows that axial load is the significant parameter that contributes by 75.67% towards MRPI, followed by transverse speed and rotational speed. Confirmation experiment with optimum condition produces a better friction stir welding joint with higher tensile strength and hardness.

Effects of friction stir welding on corrosion and mechanical properties of AA6063 in sea water

2021 ◽  
pp. 095440622199554
Author(s):  
Laxmana Raju Salavaravu ◽  
Lingaraju Dumpala
Keyword(s):  
Mechanical Properties ◽  
Electron Microscope ◽  
Friction Stir Welding ◽  
Corrosion Rate ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

Submerged friction stir welding (FSW) is used to improve the weld zones mechanical properties in the present study. This research aims to obtain the optimized process parameters used to fabricate the AA6063 Submerged FSW joint. In the Submerged FSW process, the most important influential factors are tool rotational speed, traverse speed, and pin profile in a seawater environment. The different workpieces are friction stir welded while submerged in seawater at different tool rotational speeds, traverse speeds, and tool pin profiles such as square pin, cylindrical taper pin, and threaded pin. The produced weldments were tested for the mechanical properties of higher tensile strength, microhardness, corrosion rate, and the microstructure of weldments was characterized by using a scanning electron microscope, transmission electron microscope, and X-ray diffractometer. The corrosion rate is investigated by using an electrochemical analyzer by potential dynamic polarization open-circuit technique. For this investigation, The Taguchi method with the L9 orthogonal array design of experimentation is adopted. The maximum UTS was acquired in the weld joint fabricated with 1250 r/min of tool rotational speed, 45 mm/min traverse speed, and a square tool pin. The stirred zone is tested for microhardness. High hardness is achieved with high tool rotational speed and low traverse speed with a square tool pin profile. The corrosion rate is also decreased with high tool rotational speed, low traverse speed, and a square tool pin profile.

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.

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 Tool Rotational Speed on Microstructure and Microhardness of AA6082/TiC Surface Composites using Friction Stir Processing

2014 ◽  
Vol 592-594 ◽  
pp. 234-239 ◽  
Author(s):  
A. Thangarasu ◽  
N. Murugan ◽  
I. Dinaharan ◽  
S.J. Vijay
Keyword(s):  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Composites ◽  
Homogenous Distribution ◽  
Tool Pin ◽  
Scanning Electron

Friction stir processing (FSP) is as a novel modifying technique to synthesize surface composites. An attempt has been made to synthesis AA6082/TiC surface composite using FSP and to analyze the effect of tool rotational speed on microstructure and microhardness of the same. The tool rotational speed was varied from 800 rpm to 1600 rpm in steps of 400 rpm. The traverse speed, axial force, groove width and tool pin profile were kept constant. Scanning electron microscopy was employed to study the microstructure of the fabricated surface composites. The results indicated that the tool rotational speed significantly influenced the area of the surface composite and distribution of TiC particles. Higher rotational speed provided homogenous distribution of TiC particles while lower rotational speed caused poor distribution of TiC particles in the surface composite. The effect of the tool rotational speed on microhardness is also reported in this paper.

Effect of Tool Rotational Speed and Traverse Speed on Friction Stir Welding of 3D-Printed Polylactic Acid Material

2021 ◽  
Author(s):  
S. M. Senthil ◽  
Manickam Bhuvanesh Kumar
Keyword(s):  
Friction Stir Welding ◽  
Polylactic Acid ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Butt Weld ◽  
Friction Stir ◽  
Welding Technology ◽  
Joint Efficiency ◽  
3D Printed

Joining of polymers are usually carried out using adhesives that has a deteriorating quality at elevated working conditions thus limiting its application areas. Friction stir welding (FSW) is a growing solid-state welding technology, with applications including the welding of lightweight materials. FSW was recently introduced for joining thermoplastics materials and found successful. This study attempts in employing FSW to join polylactic acid (PLA)-based 3D printed engineering components and assess the effect of FSW process parameters (tool rotational speed and traverse speed) on the weld property. The present work uses the FSW process to butt weld 5 mm thick 3D printed PLA sheets with taper cylindrical profiled tool. For the experimentation, three different combinations of feed rates and pin rotational speeds are considered. Based on joint efficiency evaluation, it is found that tool rotational speed of 1400 rpm combined with 10 mm/min transverse speed produces the weld with high joint efficiency of 40%.

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