Multi-Objective Variable Neighborhood Strategy Adaptive Search for Tuning Optimal Parameters of SSM-ADC12 Aluminum Friction Stir Welding

This research presents a novel algorithm for finding the most promising parameters of friction stir welding to maximize the ultimate tensile strength (UTS) and maximum bending strength (MBS) of a butt joint made of the semi-solid material (SSM) ADC12 aluminum. The relevant welding parameters are rotational speed, welding speed, tool tilt, tool pin profile, and rotation. We used the multi-objective variable neighborhood strategy adaptive search (MOVaNSAS) to find the optimal parameters. We employed the D-optimal to find the regression model to predict for both objectives subjected to the given range of parameters. Afterward, we used MOVaNSAS to find the Pareto front of the objective functions, and TOPSIS to find the most promising set of parameters. The computational results show that the UTS and MBS of MOVaNSAS generate a 2.13% to 10.27% better solution than those of the genetic algorithm (GA), differential evolution algorithm (DE), and D-optimal solution. The optimal parameters obtained from MOVaNSAS were a rotation speed of 1469.44 rpm, a welding speed of 80.35 mm/min, a tool tilt of 1.01°, a cylindrical tool pin profile, and a clockwise rotational direction.

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Variable Neighborhood Strategy Adaptive Search for Optimal Parameters of SSM-ADC12 Aluminum Friction Stir Welding

Processes ◽

10.3390/pr9101805 ◽

2021 ◽

Vol 9 (10) ◽

pp. 1805

Author(s):

Suppachai Chainarong ◽

Thanatkij Srichok ◽

Rapeepan Pitakaso ◽

Worapot Sirirak ◽

Surajet Khonjun ◽

...

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Welding Speed ◽

Welding Parameters ◽

Adaptive Search ◽

Optimal Parameters ◽

Friction Stir ◽

Tool Pin Profile ◽

Tool Pin ◽

Rotational Direction

In this study, we present a new algorithm for finding the optimal friction stir welding parameters to maximize the tensile strength of a butt joint made of the semisolid material (SSM) ADC12 aluminum. The welding parameters were rotational speed, welding speed, tool tilt, tool pin profile, and rotational direction. The method presented is a variable neighborhood strategy adaptive search (VaNSAS) approach. The process of finding the optimal friction stir welding parameters comprises five steps: (1) identifying the type and range of friction stir parameters using a literature survey; (2) performing experiments according to (1); (3) constructing a regression model using the response surface method optimizer (RSM optimizer); (4) using VaNSAS to find the optimal parameters for the model obtained from (3); and (5) confirming the results from (4) using the parameter levels obtained from (4) to perform real experiments. The computational results revealed that the tensile strength generated from VaNSAS was 3.67% higher than the tensile strength obtained from the RSM optimizer parameters. The optimal parameters obtained from VaNSAS were a rotation speed of 2200 rpm, a welding speed of 108.34 mm/min, a tool tilt of 1.23 Deg, a tool pin profile of a hexagon, and a rotational direction of clockwise.

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Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.789 ◽

2012 ◽

Vol 445 ◽

pp. 789-794 ◽

Cited By ~ 1

Author(s):

Vahid Moosabeiki ◽

Ghasem Azimi ◽

Mostafa Ghayoor

Keyword(s):

Friction Stir Welding ◽

Aluminium Alloy ◽

Frictional Heat ◽

Welding Parameters ◽

Zone Formation ◽

Friction Stir ◽

Tool Pin Profile ◽

Tool Shoulder ◽

Aa6061 Aluminium Alloy ◽

Tool Pin

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

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Combined Response Surface Method and Modified Differential Evolution for Parameter Optimization of Friction Stir Welding

Processes ◽

10.3390/pr8091080 ◽

2020 ◽

Vol 8 (9) ◽

pp. 1080

Author(s):

Thanatkij Srichok ◽

Rapeepan Pitakaso ◽

Kanchana Sethanan ◽

Worapot Sirirak ◽

Parama Kwangmuang

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Ultimate Tensile Strength ◽

Differential Evolution ◽

Welding Speed ◽

Tool Material ◽

Optimal Parameters ◽

Friction Stir ◽

Surface Method ◽

Tool Pin

In this study, we constructed a new algorithm to determine the optimal parameters for friction stir welding including rotational speed, welding speed, axial force, tool pin profile, and tool material. The objective of welding is to maximize the ultimate tensile strength of the welded aluminum. The proposed method combines the response surface method and the modified differential evolution algorithm (RSM-MDE). RSM-MDE is a method that involves both experimental and simulation procedures. It is composed of four steps: (1) finding the number of parameters and their levels that affect the efficiency of the friction stir welding, (2) using RSM to formulate the regression model, (3) using the MDE algorithm to find the optimal parameter of the regression model obtained from (2), and (4) verifying the results obtained from step (3). The optimal parameters generated by the RSM-MDE method were a rotation speed of 1417.68 rpm, a welding speed of 60.21 mm/min, an axial force of 8.44 kN, a hexagon-tapered tool pin profile, and the SKD 11 tool material. The ultimate tensile strength obtained from this set of parameters was 294.84 MPa, which was better than that of the RSM by 1.48%.

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Effect of Tool Geometry and Welding Speed on Mechanical Properties and Microstructure of Friction Stir Welded Joints of Aluminium Alloys AA6082-T6

Archive of Mechanical Engineering ◽

10.2478/meceng-2014-0026 ◽

2014 ◽

Vol 61 (3) ◽

pp. 455-468

Author(s):

Hiralal Subhash Patil ◽

Sanjay N. Soman

Keyword(s):

Mechanical Properties ◽

Welding Speed ◽

Welded Joints ◽

Aluminium Alloys ◽

Tensile Tests ◽

Tool Geometry ◽

Welding Parameters ◽

Friction Stir ◽

Tool Pin Profile ◽

Tool Pin

Abstract Friction stir welding is a solid state innovative joining technique, widely being used for joining aluminium alloys in aerospace, marine automotive and many other applications of commercial importance. The welding parameters and tool pin profile play a major role in deciding the weld quality. In this paper, an attempt has been made to understand the influences of welding speed and pin profile of the tool on friction stir welded joints of AA6082-T6 alloy. Three different tool pin profiles (tapered cylindrical four flutes, triangular and hexagonal) have been used to fabricate the joints at different welding speeds in the range of 30 to 74 mm/min. Microhardness (HV) and tensile tests performed at room temperature were used to evaluate the mechanical properties of the joints. In order to analyse the microstructural evolution of the material, the weld’s cross-sections were observed optically and SEM observations were made of the fracture surfaces. From this investigation it is found that the hexagonal tool pin profile produces mechanically sound and metallurgically defect free welds compared to other tool pin profiles.

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Study the Role of Friction Stir Welding Tilt Angle on Microstructure and Hardness

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.799-800.434 ◽

2015 ◽

Vol 799-800 ◽

pp. 434-438 ◽

Cited By ~ 5

Author(s):

H.A.D. Hamid ◽

A.A. Roslee

Keyword(s):

Mechanical Properties ◽

Friction Stir Welding ◽

Tilt Angle ◽

Welding Speed ◽

Rotation Speed ◽

Welding Parameters ◽

Friction Stir ◽

Tool Rotation Speed ◽

Tool Pin ◽

Tool Rotation

This paper presents an investigation of research objectives on the effect of tilt angle on microstructure and mechanical properties of dissimilar aluminum alloy sheets between AA5083 and AA6061, 5mm plates by using Friction Stir Welding (FSW) process in butt joint. The base materials of AA5083 and AA6061 were located on the retreating side (RS) and advancing side (AS), respectively. The welding process and the welding parameters such as tool pin profile, tool rotation speed, welding speed and tilt angle influenced the mechanical properties of the Friction Stir Welding joints significantly. For this experiment, the Friction Stir Welding materials joined under five different tilt angles (from 0oto 4o) with 86mm/min of welding speed and 910 rpm of tool rotation speed which were set similarly. Microscopic examination on the weld samples showed significant variation in the microstructure especially in the region of heat-affected zone (HAZ), weld nugget or dynamically recrystallized zone (DXZ) and in the base metal.

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Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/09544062211005804 ◽

2021 ◽

pp. 095440622110058

Author(s):

Sanjeev Verma ◽

Vinod Kumar

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Tilt Angle ◽

Feed Rate ◽

Aluminium Alloys ◽

Welded Joint ◽

Welding Parameters ◽

Friction Stir ◽

Industrial Sectors ◽

Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

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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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