scholarly journals Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1480
Author(s):  
Assefa Asmare ◽  
Raheem Al-Sabur ◽  
Eyob Messele
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Weight Ratio ◽  
Welding Process ◽  
Quality Criteria ◽  
Alloy Sheet ◽  
Friction Stir ◽  
Weld Joints

The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

Analysis of process parameters effects on underwater friction stir welding of aluminum alloy 6082-T6

2018 ◽  
Vol 233 (6) ◽  
pp. 1700-1710 ◽  
Author(s):  
Mohd Atif Wahid ◽  
Zahid A Khan ◽  
Arshad Noor Siddiquee ◽  
Rohit Shandley ◽  
Nidhi Sharma
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Underwater Friction Stir Welding ◽  
Optimal Setting

In friction stir welding of heat treatable aluminum alloys, the thermal cycles developed during the joining process result in softening of the joints which adversely affect their mechanical properties. Underwater friction stir welding can be a process of choice to overcome this problem due to low peak temperature and short dwell time involved during the process. Consequently, this article presents a study pertaining to the underwater friction stir welding of aluminum alloy 6082-T6 with an aim to develop a mathematical model to optimize the underwater friction stir welding process parameters for obtaining maximum tensile strength. The results of the study reveal that the tool shoulder diameter (d), tool rotational speed (ω), welding speed (v), and second-order term of rotational speed, that is, ω2, significantly affect the tensile strength of the joint. The maximum tensile strength of 241 MPa which is indeed 79% of the base metal strength and 10.7% higher than that of conventional (air) friction stir welding joint was achieved at an optimal setting of the underwater friction stir welding parameters, that is, tool rotational speed of 900 r/min, the welding speed of 80 mm/min, and a tool shoulder of 17 mm. The article also presents the results of temperature variation, the macrostructural and microstructural investigations, microhardness, and fractography of the joint obtained at the optimal setting for underwater friction stir welded (UFSWed) joint.

An Experimental Study of Process Parameters on Friction Stir Welded Aluminum Alloy 2219 Joint Properties

2017 ◽  
Vol 863 ◽  
pp. 3-7
Author(s):  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon ◽  
Ho Sung Lee
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Process Parameters ◽  
Process Condition ◽  
Welding Process ◽  
Frictional Heat ◽  
Friction Stir ◽  
Joint Properties ◽  
Aluminum Alloy 2219

Aluminum alloy 2219 is widely used in aerospace applications since it has a unique combination of good weldability and high specific strength. Furthermore, it can provide a high strength after heat treatment with superior properties in cryogenic environment so they have been widely used for cryogenic fuel tank of space launch vehicles. It is known that solid state welding like friction stir welding can improve the joint properties of this alloy. Friction stir welding is a solid state welding technology which two materials are welded together by the frictional heat due to the rotation of the tool. In this study, friction stir welding was performed on aluminum alloy 2219 sheets. The range of welding parameter is four rotation speeds from 350 to 800 rpm and six travel speeds from 120 to 420 mm/min. The results include the microstructural change after friction stir welding. The microstructure was characterized and material in the stirred zone experience sufficient deformation and heat input which cause the complete dynamic recrystallization. The present work represents the strength at each process condition and the optimum friction stir welding process parameters. The optimum weld efficiency obtained in this study was 76.5 %.

scholarly journals Effect of process parameters on mechanical properties of AA5052 joints using underwater friction stir welding

2020 ◽  
Vol 14 (1) ◽  
pp. 6259-6271
Author(s):  
Srinivasa Rao Pedapati ◽  
Dhanish Paramaguru ◽  
Mokhtar Awang ◽  
Hamed Mohebbi ◽  
Sharma V Korada
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Welding Parameters ◽  
Fracture Characterization ◽  
Friction Stir ◽  
Weld Joints ◽  
Underwater Friction Stir Welding

Underwater Friction Stir Welding (UFSW) is a solid-state joining technique which uses a non-consumable tool to weld metals. The objective of this investigation is to evaluate the mechanical properties of the AA5052 Aluminium alloy joints prepared by UFSW. The effect of different type of welding tools and welding parameters on the weld joint properties are studied. Square, tapered cylindrical and taper threaded cylindrical type of welding tools have been used to produce the joints with the tool rotational speed varying from 500 rpm to 2000 rpm while the welding speed varying from 50 mm/min to 150 mm/min. Tensile strength, micro-hardness distribution, fracture features, micro-and macrostructure of the fabricated weld joints have been evaluated. The effect of welding process parameters that influences the mechanical properties and fracture characterization of the joints are explained in detail. A maximum Ultimate Tensile Strength (UTS) value of 222.07 MPa is attained with a gauge elongation of 14.78%. Microstructural evaluation revealed that most of the fracture are found on the thermal mechanically affected zone (TMAZ)adjacent to the weld nugget zone (WNZ) due to bigger grain sizes. It is found that most of the joints exhibit ductile characteristics in failure. Fractography analysis has been used to find the behavior of weld joints in failure.

scholarly journals Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

2017 ◽  
Vol 37 (1) ◽  
pp. 6-21 ◽  
Author(s):  
C. Rajendrana ◽  
K. Srinivasan ◽  
V. Balasubramanian ◽  
H. Balaji ◽  
P. Selvaraj
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Weight Ratio ◽  
Welding Process ◽  
Lap Joints ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir

AbstractAA2014 aluminum alloy (Al-Cu alloy) has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW) parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE), analysis of variance (ANOVA), response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5°.

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