scholarly journals Forecasting process parameters on weld nugget hardness of filler added friction stir welded dissimilar aluminium alloys 5052 And 6082 joints

2021 ◽  
Vol 5 (2) ◽  
pp. 103-112
Author(s):  
A. Sasikumar ◽  
S. Gopi ◽  
Dhanesh G. Mohan
Keyword(s):  
Aluminium Alloy ◽  
Process Parameters ◽  
Welding Speed ◽  
Welding Process ◽  
Prediction Equation ◽  
Weld Nugget ◽  
Plunge Depth ◽  
Friction Stir ◽  
Central Composite ◽  
Center Distance

This article deals with the optimization of friction stir welding process parameters with filler ratios on dissimilar Aluminium alloy groups. For this purpose, 6 series Aluminium alloy 6082 and 5 series Aluminium alloy 5052 were taken. Microhardness property was conducted under various rotational speeds, welding speed, plunge depth, Center distance between the holes and filler mixing ratio. The Central Composite Design (CCD), the most commonly used Response Surface Methodology (RSM), is considered to develop the prediction equation. A validation analysis is carried out, and the results were compared with the relative impact of input parameters on weld nugget microhardness. It is observed that the increase in welding speed with plunge depth and filler ratio result in the increase of weld nugget microhardness up to a maximum value. The maximum weld nugget hardness of fabricated joint was obtained with the welding process parameters combination of 1000 rpm rotational speed, 125 mm/min welding speed, 0.15 mm plunge depth, 2 mm centre distance between the holes, and filler ratio of 95% Mg and 5% Cr.

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

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
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.

Comparison of ANN Training Algorithms for Predicting the Tensile Strength of Friction Stir Welded Aluminium Alloy AA1100

2018 ◽  
Vol 10 (2) ◽  
Author(s):  
R.V. Vignesh ◽  
R. Padmanaban
Keyword(s):  
Tensile Strength ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Network Architecture ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength ◽  
Training Algorithms ◽  
Friction Stir ◽  
Propagation Network

Aluminium alloy AA1100 finds application in light weight structures due to its high strength to weight ratio. Friction stir welding is a solid state welding process, in which the materials are joined in the plasticized state. The quality of the friction stir welded joints depends on the process parameters used and tool parameters. In this study, four process parameters were varied at five levels and experimental trials were performed as per face centered central composite design. Artificial neural network model was developed with cascade forward propagation network architecture and trained with LM algorithm and BFGS QN algorithm. The models were used to predict the tensile strength of the joints and the error in prediction was used to judge the accuracy of the developed models. It is observed that BFGS QN algorithm trains the ANN efficiently and results in accurate predictions.

Influence of Welding Process Parameters on Microstructure and Mechanical Properties of Friction Stir Welded Aluminium Matrix Composite

2016 ◽  
Vol 880 ◽  
pp. 50-53 ◽  
Author(s):  
Subramanya Prabhu ◽  
Arun Kumar Shettigar ◽  
Karthik Rao ◽  
Shrikantha Rao ◽  
Mervin Herbert
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Joint Strength ◽  
Welding Process ◽  
Aluminium Matrix ◽  
Friction Stir ◽  
Weld Region ◽  
Microstructure And Mechanical Properties

In this study, the effect of process parameters on microstructure and mechanical properties of friction stir welded aluminium matrix composites (AMC) have been explored. The results indicated that the recrystallized grain size at the bottom of the weld region is smaller than that at the top region due to difference in the heat transfer at the weld region. The joint strength of AMCs depends on proper selection of process parameters like tool rotational speed and welding speed. If process parameter values are beyond the optimal value, the joint strength decreases due to formation of defects. Maximum tensile strength is obtained for rotational speed of 1000 rpm and welding speed of 80mm/min.

scholarly journals Optimization of Friction Stir Welding Process Parameters of Aluminium alloy AA7075-T6 by using Taguchi Method

2019 ◽  
Vol 8 (12) ◽  
pp. 290-297
Keyword(s):  
Tensile Strength ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Mechanical Characteristics ◽  
Parametric Design ◽  
Welding Process ◽  
Optimization Method ◽  
Friction Stir ◽  
Aa 7075 ◽  
Optimal Values

Taguchi technique has been used to determine the most important control variables that will result in greater mechanical characteristics (tensile strength and hardness) of FSW joints of comparable AA 7075 plates. To optimize process parameters including tool rotatory speed, weld travel velocity on tensile strength and hardness of friction stir welded similar AA 7075 aluminium alloy, Taguchi Design of Experiment (DOE) and optimization method was used. The optimum levels of process parameters were identified by using the Taguchi parametric design concept. The results show that welding speed is more contributing process parameter than the rotation speed in getting optimum mechanical property (UTS and HV). The forecasted optimal values of ultimate tensile strength and hardness of friction stir welded similar AA 7075 is 197 Mpa and 93 HRB respectively. Further tests proved these results

scholarly journals Friction Stir Welding of Wrought Aluminium Alloy EN AW- 6082

2021 ◽  
pp. 15-24
Author(s):  
Damian Miara
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Welding Process ◽  
Test Results ◽  
Friction Stir ◽  
Strength Tests ◽  
Structural Tests ◽  
Tool Rotation

The article presents results of the friction stir welding of 6 mm thick plates made of wrought aluminium alloy EN AW-6082. Tests discussed in the article involved the identification of the effect of primary welding process parameters on the quality of welds. Test welds were subjected to visual tests, measurements of temperature (inside the weld), tensile strength tests as well as macro and microscopic metallographic tests and structural tests (performed using a scanning electron microscope). The application of the appropriate values of the primary welding process parameters (i.e. the tool rotation rate and the welding rate) enabled the obtainment of the high and repeatable quality of FSW joints made of aluminium alloy EN AW-6082. The test results presented in the article can offer technological solutions for potential

Microstructural and Mechanical Characterization of Friction Stir Welded- 1050 Aluminium Alloy

2009 ◽  
Vol 83-86 ◽  
pp. 1173-1181
Author(s):  
Magdy M. El Rayes ◽  
Ehab A. El-Danaf ◽  
Mahmoud S. Soliman
Keyword(s):  
Welding Speed ◽  
Rotational Speed ◽  
Welding Process ◽  
Grain Structure ◽  
Weld Nugget ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Work Piece ◽  
Tool Rotational Speed ◽  
Friction Stir

Friction stir welding (FSW) is a fairly recent technique that utilizes a non-consumable rotating welding tool to generate frictional heat and plastic deformation at the welding location in the continuously-fed work piece. In the present investigation this welding process is applied to join 1050 cold-rolled aluminium plates. The effects of varying the welding parameters namely welding speed [56, 90 and 140 mm/min] and tool rotational speed [850 and 1070 rpm] on the mechanical and microstructural properties were studied. Vickers micro hardness results across the weldment showed that the weld nugget hardness is dependant upon the welding speed and the tool rotational speed. Increasing the welding speed at 850 rpm reduced the hardness at the weld nugget, whereas, at 1070 rpm the weld nugget hardness merely did not change. However, the hardness achieved at 850 rpm was constantly higher than that achieved with 1070 rpm irrespective to welding speeds. In the same fashion, the yield and ultimate strengths of the joints were influenced by varying the welding parameters. Increasing the welding speed at 850 rpm reduced both strengths whereas; at 1070 rpm they were almost unchanged. Microstructural study showed that the weld region is composed of unaffected base metal and the stir zoned [weld nugget] which is characterised by a fine equiaxed grain structure. Increasing the welding speed at constant tool rotational speed has caused a slight refinement in the weld nugget's grain size, whereas, decreasing the rotational speed has also led to weld nugget grain refinement.

Multi-response optimization of friction stir corner welding of dissimilar thickness AA5086 and AA6061 aluminum alloys by Taguchi grey relational analysis

2018 ◽  
Vol 233 (11) ◽  
pp. 3733-3742 ◽  
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Aluminum Alloys ◽  
Process Parameters ◽  
Welding Speed ◽  
Grey Relational Analysis ◽  
Plunge Depth ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational ◽  
Tool Rotation ◽  
Dissimilar Thickness

Friction stir welding is a promising solid-state joining process to weld light materials like aluminum alloys. In this paper, an attempt has been made to optimize the friction stir corner welding process parameters using Taguchi grey relational analysis to attain the improved mechanical properties of dissimilar thickness AA5086 and AA6061 dissimilar aluminum alloys with plate thicknesses of 6 mm and 4 mm, respectively. The input parameters of the welding play a crucial role to achieve the desired weld properties. The friction stir welding experiments were conducted according to the L9 orthogonal array. The input process parameters are tool rotation speed (900–1100 r/min), welding speed (100–190 mm/min), and plunge depth (0.1–0.3 mm). The processes parameters were optimized and ranked based on the results of the grey relational analysis. The percentage contribution of each input process parameter on the weld quality was quantified using analysis of variance (ANOVA). The optimal process parameters were determined at tool rotation speed of 1100 r/min, welding speed of 150 mm/min, and tool plunge depth of 0.2 mm. The percentage contribution of the welding speed was 40.50% and revealed a significant influence on multiple responses followed by plunge depth 25.84% and rotational speed 18.13%. The microstructures of various regions were observed and analyzed. The fracture mode and fracture surface of the welded sample were observed and discussed.

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