Investigation and optimization of friction stir welding process parameters of stir cast AA6082/ZrO2/B4C composites

Abstract In the present investigation, aluminium-based alloy (AA6082) is stir-casted with 3 % ZrO2 and 5 % B4C reinforcement particulates to fabricate Aluminium Metal Matrix Hybrid Composites (AMMHCs) which are further friction-stir welded at different welding conditions to develop a welded joint with optimum ultimate tensile strength (UTS) and microhardness. This newly developed AMMHC will find its specific application as bulkhead partitions in the hull of a ship due to its excellent properties, such as lower weight, higher specific strength, superior resistance to wear, and lower thermal expansion coefficient than that of AA6061 and AA5083 composites. The friction-welded butt joints performance of AA6082/3%ZrO2/5%B4C is generally determined by varying the FSW process parameters such as tool rotational speed (TRS), welding speed (WS), axial load (AL), tool tilt angle (TTA), tool pin profile (TPP), shoulder diameter (SD), etc. In the present work, the empirical relationships are established between parameters highly influencing FSW process (TRS, WS, and AL) and their responses (UTS and weld nugget microhardness (WNH)). The desirability approach is employed for predicting the optimal UTS and WNH. The corresponding values of input process parameters are TRS of 1030.95 rpm, WS of 38.5 mm/min, and AL of 5.88 kN. The calculated UTS and WNH for the present investigation are 239.98 MPa and 94.2 HV, respectively, and these values are consistent with the results of validation experiments.

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Multi Response Optimization of Submerged Friction Stir Welding Process Parameters Using TOPSIS Approach

Volume 2B: Advanced Manufacturing ◽

10.1115/imece2015-50353 ◽

2015 ◽

Cited By ~ 1

Author(s):

Senthil Kumar Velukkudi Santhanam ◽

Lokesh Rathinaraj ◽

Rathinasuriyan Chandran ◽

Shankar Ramaiyan

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Welding Process ◽

Fusion Welding ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Response Characteristics ◽

Response Optimization ◽

Topsis Approach ◽

Tool Pin

Friction stir welding (FSW) is a solid-state welding process which is used to join high-strength aircraft aluminum alloys and other metallic alloys which are difficult to weld by conventional fusion welding. In this paper, AA6063-O alloy of 6mm thickness was taken and friction stir welded under the water in order to improve the joint properties. The process parameters considered as rotational speed, welding speed and tool pin profiles (cylindrical, threaded and tapered) are optimized with multi response characteristics including hardness, tensile strength and % elongation. In order to solve a multi response optimization problem, the traditional Taguchi approach is insufficient. To overcome this constraint, a multi criteria decision making approach, namely, techniques for order preference by similarity to ideal solution (TOPSIS) is applied in the present study [13]. The optimal result indicates that the multi response characteristics of the AA6063-O during the submerged friction stir welding process can be enhanced through the TOPSIS approach. The Analysis of Variance (ANOVA) was carried out to investigate the significant parameter for the submerged friction stir welding process. The mechanical properties of the submerged FSW are compared with normal FSW joints.

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Influence of Tool Tilt Angle on Material Flow and Defect Generation in Friction Stir Welding of AA2219

Defence Science Journal ◽

10.14429/dsj.68.12027 ◽

2018 ◽

Vol 68 (5) ◽

pp. 512-518 ◽

Cited By ~ 10

Author(s):

Suresh Meshram ◽

Madhusudhan Reddy

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Tilt Angle ◽

Material Flow ◽

Critical Role ◽

Welding Process ◽

Fusion Welding ◽

Friction Stir ◽

Tool Tilt Angle ◽

Welding Processes

Heat treatable aluminium alloy AA2219 is widely used for aerospace applications, welded through gas tungsten and gas metal arc welding processes. Welds of AA2219 fabricated using a fusion welding process suffers from poor joint properties or welding defects due to melting and re-solidification. Friction stir welding (FSW) is a solid-state welding process and hence free from any solidification related defects. However, FSW also results in defects which are not related to solidification but due to improper process parameter selection. One of the important process parameters, i.e., tool tilt angle plays a critical role in material flow during FSW, controlling the size and location of the defects. Effect of tool tilt angle on material flow and defects in FSW is ambiguous. A study is therefore taken to understand the role of tool tilt angle on FSW defects. Variation in temperature, forces, and torque generated during FSW as a result of different tool tilt angles was found to be responsible for material flow in the weld, controlling the weld defects. An intermediate tool tilt angle (1o-2o) gives weld without microscopic defect in 7 mm thick AA2219 for a given set of other process parameters. At this tool tilt angle, x-force, and Z- force is balanced with viscosity and the material flow strain rate sufficient for the material to flow and fill internal voids or surface defects in the weld.

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Multi Response Optimization of Process Parameters on AA8011 Friction Stir Welded Aluminium Alloys Using RSM Based GRA Coupled with DEA

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.813-814.446 ◽

2015 ◽

Vol 813-814 ◽

pp. 446-450 ◽

Cited By ~ 10

Author(s):

K. Palani ◽

C. Elanchezhian

Keyword(s):

Process Parameters ◽

Tilt Angle ◽

Feed Rate ◽

Rotational Speed ◽

Aluminium Alloys ◽

Welding Process ◽

Fusion Welding ◽

Gray Relational Analysis ◽

Friction Stir ◽

Tool Tilt Angle

The friction stir welding process is the newly developed material joining process used to join the different materials which are very difficult to join in the conventional fusion welding process. In this investigation using the specially designed straight cam profiled tool, the multiple responses of Ultimate tensile strength, Ultimate yield strength and Percentage of elongation with the process parameters of rotational speed, tool tilt angle and feed rate are optimized. The five level, three factor rotatable central composite design is selected to optimize the responses of friction stir welded AA 8011 aluminium alloys. The highest gray relational grade with the highest relative efficiency is found using the gray relational analysis coupled with the data envelopment analysis to predict the optimum parameters. It exposes that at the rotational speed of 680 rpm, the tool tilt angle of 98 degrees and the feed rate of 24 mm/min the good weld quality can be attained.

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Multi objective optimization of process parameters of AA2014 Friction Stir Weldments using Genetic Algorithm

INCAS BULLETIN ◽

10.13111/2066-8201.2020.12.3.15 ◽

2020 ◽

Vol 12 (3) ◽

pp. 183-193

Author(s):

L. Suvarna RAJU ◽

Borigorla VENU ◽

G. MALLAIAH

Keyword(s):

Mechanical Properties ◽

Genetic Algorithm ◽

Process Parameters ◽

Welding Speed ◽

Objective Functions ◽

Multi Objective Optimization ◽

Friction Stir ◽

Optimization Of Process Parameters ◽

Tool Tilt Angle ◽

Tool Pin

The influence of tool pin profile and process parameters on microstructure and mechanical properties of AA2014 weldments was studied. Tool pin profiles such as a Straight Cylindrical Threaded (SCT) and Taper Cylindrical Threaded (TCT) profiles are used for experimentation. The process parameters such as constant tool rotational speed of 900 rpm, welding speed and tool tilt angles at 30, 40, 50, and 60mm/min and 1o, 2o, respectively, are used to fabricate the weldments. A set of experiments was conducted with two different tool pin profiles and mechanical properties were evaluated. The better mechanical properties such as tensile strength of 367N/mm2, impact strength of 10J and hardness of 139HV were obtained by using TCT pin when compared to SCT pin. The observed mechanical properties have been correlated with microstructure. The mechanical properties were analyzed by ANOVA and regression analysis. Objective functions and constraints are developed for the three responses in terms of factors. The factors are optimized using Genetic Algorithm (GA). From the GA results, it is observed that the welding speed of 58mm/min and tool tilt angle of 1.95o are found to be the better combination for carrying out the experiments using TCT pin profile.

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Comparison of the Optimized Process Parameters of Double-Sided Friction Stir Welded Aluminium Alloy Joints Using Statistical and Evolutionary Techniques

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.852.317 ◽

2016 ◽

Vol 852 ◽

pp. 317-323 ◽

Cited By ~ 2

Author(s):

S. Vignesh ◽

P. Dinesh Babu ◽

C. Balamurugan ◽

S. Martin Vinoth

Keyword(s):

Response Surface Methodology ◽

Evolutionary Algorithm ◽

Response Surface ◽

Process Parameters ◽

Welding Speed ◽

Rotational Speed ◽

Welding Process ◽

Regression Equations ◽

Friction Stir ◽

Desirability Approach

One of the most innovative solid state welding techniques used in the aerospace, automotive, defence, rail and marine industries is Friction Stir Welding (FSW) process, as it is used for joining aluminium, copper and magnesium alloys. The weld quality is decided by the FSW process parameters such as rotational speed, welding speed and pin profile. A regression model was developed relating the welding input parameters (tool rotational speed, welding speed and pin profile) and the output response parameters (tensile strength, hardness and toughness) based on the experiments carried out with the help of Response Surface Methodology. The obtained regression equations were used in determining the optimal welding process parameters. A new method, Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) based on evolutionary algorithm has been used in the optimisation. The optimum results gathered from the desirability approach through Response Surface Methodology (RSM) were compared with those obtained through the evolutionary algorithm. The results show that the proposed evolutionary method is much effective, faster than the desirability approach discussed in the work.

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Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.622-623.323 ◽

2012 ◽

Vol 622-623 ◽

pp. 323-329

Author(s):

Ebtisam F. Abdel-Gwad ◽

A. Shahenda ◽

S. Soher

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Welding Process ◽

Tensile Behavior ◽

Frictional Heat ◽

Welding Parameters ◽

Friction Stir ◽

Aluminum Base ◽

Tool Pin ◽

Strength And Ductility

Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.

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Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

MATEC Web of Conferences ◽

10.1051/matecconf/201817803003 ◽

2018 ◽

Vol 178 ◽

pp. 03003 ◽

Cited By ~ 1

Author(s):

Ana Bosneag ◽

Marius Adrian Constantin ◽

Eduard Niţu ◽

Monica Iordache

Keyword(s):

Friction Stir Welding ◽

Aluminium Alloy ◽

Process Parameters ◽

Arc Welding ◽

Welding Process ◽

Dissimilar Materials ◽

Workpiece Material ◽

Friction Stir ◽

Welding Joints ◽

Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

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Fabrication of AA7075 Hybrid Green Metal Matrix Composites by Friction Stir Processing Technique

Annales de Chimie Science des Matériaux ◽

10.18280/acsm.440409 ◽

2020 ◽

Vol 44 (4) ◽

pp. 295-300

Author(s):

Sanjay Kumar ◽

Ashish Kumar Srivastava ◽

Rakesh Kumar Singh

Keyword(s):

Mechanical Properties ◽

Process Parameters ◽

Friction Stir Processing ◽

Research Work ◽

Processing Technique ◽

Matrix Composites ◽

Avant Garde ◽

Friction Stir ◽

Surface Composites ◽

Tool Tilt Angle

Friction stir processing is an avant-garde technique of producing new surface composite or changing the different properties of a material through intense, solid-state localized material plastic deformation. This change in properties depends upon the deformation formed by inserting a non-consumable revolving tool into the workpiece and travels laterally through the workpiece. This research work highlights the effect of process parameters on mechanical properties of fabricated surface composites by friction stir processing. By using various reinforcing materials like Ti, SiC, B4C, Al2O3 with waste elements like waste eggshells, rice husks, coconut shell and coir will be used to fabricate the green composites which are environmentally friendly and reduces the problem of decomposition. The parameter for this experiment is considered as the reinforcing materials, tool rotation speed and tool tilt angle. The SiC/Al2O3/Ti along with eggshell are selected asreinforcement materials. The main effect of the reinforcement is to improve mechanical properties, like hardness, impact strength and strength. The results revealed that the process parameters significantly affect the mechanical properties of friction stir processed surface composites.

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