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

Processes ◽  
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%.

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

Processes ◽  
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.

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

2021 ◽  
Vol 5 (4) ◽  
pp. 123
Author(s):  
Suppachai Chainarong ◽  
Rapeepan Pitakaso ◽  
Worapot Sirirak ◽  
Thanatkij Srichok ◽  
Surajet Khonjun ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Parameters ◽  
Adaptive Search ◽  
Optimal Parameters ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Multi Objective ◽  
Tool Pin ◽  
Objective Variable

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.

Friction Stir Welding of Dissimilar AA7075-T6 to AZ31B-H24 Alloys

MRS Advances ◽  
2017 ◽  
Vol 2 (64) ◽  
pp. 4055-4063 ◽  
Author(s):  
D. Hernández-García ◽  
R. Saldaña-Garcés ◽  
F. García-Vázquez ◽  
E.J. Gutiérrez-Castañeda ◽  
R. Deaquino-Lara ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Joint Line ◽  
Friction Stir ◽  
Tool Offset ◽  
Tool Tilt Angle

AbstractIn the present investigation, AA7075-T6 alloys and AZ31B-H24 were joined by the FSW process using the following range of parameters: rotational speed between 200 and 800 rpm, welding speed from 30 to 60 mm/min and a tilt angle from 1° to 3°. In some cases, a tool offset of 1 mm was used into Mg-based alloy. The experimental results show that sound and good joints can be obtained by positioning the tool in the middle of the joint-line using a rotational speed of 200 rpm, a welding speed of 30 mm/min and a tool tilt angle of 1°. The hardness and ultimate tensile strength in the stir zone were 122 Hv and 61.35 MPa, respectively. Also, it is important to mention that the Al3Mg2 and Al12Mg17 intermetallics compounds were observed in the this zone besides some defects like cavities and tunnel.

Multi-response optimization of friction stir welding process parameters for dissimilar joining of Al6101 to pure copper using standard deviation based TOPSIS method

2019 ◽  
Vol 233 (18) ◽  
pp. 6473-6482 ◽  
Author(s):  
Nidhi Sharma ◽  
Zahid A Khan ◽  
Arshad Noor Siddiquee ◽  
Mohd Atif Wahid
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Welding Speed ◽  
Welding Process ◽  
Micro Hardness ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Response Optimization

Friction stir welding is a new and effective solid-state welding process for joining dissimilar materials such as aluminum (Al) and copper (Cu). Joint quality of the friction stir welded materials gets influenced by the welding strategy and different friction stir welding process parameters, i.e. rotational speed, welding speed, tool design, tool pin offset, and tilt angle. In this paper, the effect of combination of different friction stir welding process parameters during joining of Al-6101 and pure copper is studied using Taguchi L18 orthogonal array. Four friction stir welding process parameters, i.e. shoulder diameter (A), pin offset (B), welding speed (C), and rotational speed (D) each at three levels except shoulder diameter, which is at two levels are selected. The effect of different combinations of these parameters on ultimate tensile strength and micro-hardness of the joints is investigated. Subsequently, single response optimization for ultimate tensile strength and micro-hardness and multi-response optimization of ultimate tensile strength and micro-hardness taken together is carried out to obtain the optimal combination of the friction stir welding process parameters. Taguchi method is used for single response optimization, whereas Taguchi-based TOPSIS method is employed for multi-response optimization. For single optimization, the optimum combination of the friction stir welding parameters yielding maximum strength and micro-hardness are A1B1C2D2 and A2B1C2D3, respectively. The optimum combination of the process parameters for multi-response optimization is A2B1C2D2. From the results of the study for single- and multi-response optimization, it is revealed that the rotational speed is the most significant process parameter affecting the tensile strength and micro-hardness of the joints followed by the welding speed. Further, the macro/microstructure and micro-hardness profile of the joint obtained at the optimal combination of the multi-response optimization are given and discussed for better understanding of material mixing and joining.

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

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.

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

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.

scholarly journals Investigations on force generation and joint properties of dissimilar thickness friction stir corner welded AA 5086 alloy

2020 ◽  
Vol 40 (1) ◽  
pp. 67-74
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Process ◽  
Spindle Motor ◽  
Parent Material ◽  
Force Generation ◽  
Friction Stir ◽  
Current Consumption ◽  
Spindle Motor Current

The force generation, joint mechanical and metallurgical properties of friction stir corner welded non-heat treatable AA 5086 aluminum alloy are investigated in this paper. The friction stir welding process is carried out with the plate thicknesses of 6 mm and 4 mm. The welding speed, tool rotational speed and tool plunge depth were considered as the process parameters to conduct the welding experiments. The machine spindle motor current consumption and tool down force generation during friction stir welding were analyzed. The microstructures of various joint regions were observed. The tensile samples revealed the tensile strength of 197 MPa with tool rotational and welding speeds of 1,000 rev/min and 150 mm/min respectively, which is 78 % of parent material tensile strength. A maximum micro hardness of 98 HV was observed at thermomechanically joint affected zone, which was welded with tool rotation of 1,000 rev/min and welding speed of 190 mm/min.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

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