scholarly journals Experimental Analysis and Optimization to Maximize Ultimate Tensile Strength and Ultimate Elongation of Friction Stir Welded AA6082 Aluminum Alloy

Metals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 69
Author(s):  
Michela Simoncini ◽  
Antonio Costa ◽  
Sergio Fichera ◽  
Archimede Forcellese
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Experimental Tests ◽  
Welding Parameters ◽  
Friction Stir ◽  
Ultimate Elongation ◽  
Welding Processes

Friction stir welding (FSW) is a well-established welding technique, which allows joining abutting surfaces by generating heating through a rotating and translating tool specifically shaped. Differently from the conventional techniques, continuous welding processes can be executed by FSW, thus supporting the economy of scales objectives. This paper deals with the selection of the optimal process parameters for the FSW of the AA6082 aluminum alloy. Three welding parameters, namely tool plunging, rotational speed and welding speed, have been handled as independent variables for developing two mathematical models by means of a non-linear regression-based approach, with the aim of predicting both ultimate tensile strength and ultimate elongation of the welded joints. A set of additional experimental tests has been used to validate the mentioned metamodels and finally three different metaheuristic algorithms have been implemented for selecting the best process parameters able to maximize the aforementioned mechanical properties. A comparison analysis based on further experimental tests confirmed the accuracy of the predicting metamodels and the quality of solutions yielded by the proposed optimization approaches.

Effect of Process Parameters on Mechanical Characterization of Dissimilar Friction Stir Welded Aluminium Alloys

2015 ◽  
Vol 766-767 ◽  
pp. 701-704
Author(s):  
R. Ramesh ◽  
S. Suresh Kumar ◽  
R.V. Srinivasan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Weight Ratio ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Axial Forces ◽  
Tool Pin

Aluminum alloys exhibit poor weldability by conventional fusion welding process. The heat treatable aluminum alloy AA2014 is extensively used in the aircraft industry because it has good ductility and high strength to weight ratio. In this paper the effects of welding parameters and tool profile on the mechanical properties of friction stir welded butt joints of dissimilar aluminum alloy sheets AA6082 and AA2014. The process parameters such as rotational speed, transverse speed and axial forces were considered. The effect of parameters on weld quality was analyzed. Hardness and tensile tests are carried out at room temperature to examine the mechanical properties of the welded joints. The joints produced with straight square tool pin profile have higher ultimate tensile strength, whereas the straight cylindrical tool pin profile results in lower tensile strength.

A Study on Grain Size, Mechanical Properties and First Mode of Metal Transfer in Underwater Friction Stir Welded AA5052-O

2018 ◽  
Vol 775 ◽  
pp. 466-472 ◽  
Author(s):  
K. Tejonadha Babu ◽  
S. Muthukumaran ◽  
C. Bharat Kumar
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Metal Transfer ◽  
Welding Parameters ◽  
Friction Stir ◽  
Second Mode ◽  
Underwater Friction Stir Welding

Friction stir welding (FSW), a new joining process is finding extensive use in the welding of aluminum alloy sheets. The metal transfer modes in the FSW cause the quality of the weld and its properties. The first mode of metal transfer is accomplished by the tool and shoulder, while the second mode occurs around the pin. In the present study, two different welding conditions, which were friction stir welding in the air (CFSW) and underwater friction stir welding (UWFSW) carried out at various welding parameters to weld the AA5052-O aluminum alloy sheets and determine the consequence of the first mode on the tensile strength of welded joints. Considerable grain refinement and enhanced mechanical properties were obtained in UWFSW joints. It Is observed that the first mode affect the tensile strength of the joint, also found that a linear correlation between the first mode and the tensile strength.

scholarly journals The Optimum Process Parameter of Dissimilar Metal AA6061 – AISI304 Continuous Drive Friction Welding

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Totok Suwanda ◽  
Rudy Soenoko ◽  
Yudy Surya Irawan ◽  
Moch. Agus Choiron
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Friction Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Dissimilar Metals ◽  
Maximum Tensile Strength ◽  
Friction Pressure ◽  
Welding Processes

This article explains the use of the response surface method to produce the optimum tensile strength for the joining of dissimilar metals with the continuous drive friction welding method. The joining of dissimilar metals is one of the biggest challenges in providing industrial applications. Continuous drive friction welding has been extensively used as one of the important solid-state welding processes. In this study, the optimization of the friction welding process parameters is established to achieve the maximum tensile strength in AA6061 and AISI304 dissimilar joints via the response surface methodology. The effect of continuous drive friction welding parameters, which are friction pressure, friction time, upset pressure, and upset time, are investigated using response surface analysis. The design matrix factors are set as 27 experiments based on Box-Behnken. The 3D surface and the contour is plotted for this model to accomplish the tensile strength optimization. The optimization model of the tensile strength was verified by conducting experiments on the optimum values of the parameters based on the experimental data results. It can be denoted that the optimum process parameters settings were friction pressure = 25 MPa, friction time = 6 seconds, upset pressure = 140 MPa, and upset time = 8 seconds, which would result in a maximum tensile strength of 228.57 MPa.

scholarly journals Application of Taguchi technique to optimize the gma welding parameters and study of fracture mode characterization of AISI 304H welded joints

2018 ◽  
Vol 9 (1) ◽  
pp. 9-16
Author(s):  
S. A. Rizvi
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Flow Rate ◽  
Fracture Mode ◽  
Welded Joints ◽  
Gas Flow ◽  
Welding Parameters ◽  
Taguchi Technique ◽  
Gas Flow Rate

This research article is focusing on the optimization of different welding process parameters which affect the weldability of stainless steel (AISI) 304H, Taguchi technique was used to optimize the welding parameters and the fracture mode characterization was studied. A number of experiments have been conducted. L9 orthogonal array (OA) (3×3) was applied. Analysis of variance ( ANOVA) and signal to noise ratio (SNR) was applied to determine the effect of different welding parameters such as welding current, wire feed speed and gas flow rate on mechanical, microstructure properties of SS304H. Ultimate tensile strength (UTS), toughness, microhardness (VHN), and mode of fracture was examined to determine weldability of AISI 304H and it was observed from results that welding voltage has major impact whereas gas flow rate has minor impact on ultimate tensile strength of the welded joints. Optimum process parameters were found to be 23 V, 350 IPM travel speed of wire and 15 l/min gas flow rate for tensile strength and mode of fracture was ductile fracture for tensile test specimen.

Heat Transfer Simulations and Analysis of Joint Cross-Sectional Microstructure on Friction Stir Welding between Steel and Aluminium

2020 ◽  
Vol 863 ◽  
pp. 85-95
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tu Vinh Thong ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Thermal Contact ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Sem Images ◽  
Cross Sectional ◽  
Friction Stir

This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between Aluminium and steel, and (3) The welding process using stiring friction is simulated. The simulations intended to predicting the temperature which is used for preheat and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength is carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed and offset), temperature and tensile strength. The maximum tensile strength is 77% compared to the strength of aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving good quality of welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments

2016 ◽  
Vol 232 (8) ◽  
pp. 1384-1394 ◽  
Author(s):  
R Palanivel ◽  
RF Laubscher ◽  
S Vigneshwaran ◽  
I Dinaharan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Ultimate Tensile Strength ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.

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