scholarly journals Design Analysis and Effect of Process Parameters on „Fsbw‟ of Al (2618a)-SIC Alloy

2020 ◽  
Vol 9 (3) ◽  
pp. 3408-3412
Keyword(s):  
Silicon Carbide ◽  
Tensile Strength ◽  
Process Parameters ◽  
Design Analysis ◽  
Tool Rotational Speed ◽  
Butt Welding ◽  
Plunge Depth ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Tilting Angle

The research in fabrication engineering is much focused on the new or betterment in the existing metal joining techniques. In the view of the demand in improvement of the quality , strength and efficiency of welded joins , the present research is focused on design for tensile strength and optimization of friction stir butt welding(FSBW)of aluminum(2618A) and silicon carbide alloy. The design analysis is carried out for tensile strength and hardness. . The functioning parameters such as tool rotational speed, transverse speed, plunge depth and tilting angle are considered. The Taguichi technique and ANOVA are used in optimization of process parameters. The high S/N ratios are mainly considered to analyze the results for tensile strength and hardness.

scholarly journals Effect of Backing Plate Materials in Micro-Friction Stir Butt Welding of Dissimilar AA6061-T6 and AA5052-H32 Aluminum Alloys

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 933
Author(s):  
SeongHwan Park ◽  
YoungHwan Joo ◽  
Myungchang Kang
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Heat Loss ◽  
Butt Joint ◽  
Thin Plates ◽  
Butt Welding ◽  
Friction Stir ◽  
Backing Plate ◽  
Base Materials ◽  
Tilting Angle

Thin sheets of lightweight aluminum alloys, which are increasingly used in automotive, aerospace, and electronics industries to reduce the weight of parts, are difficult to weld. When applying micro-friction stir welding (μ-FSW) to thin plates, the heat input to the base materials is considerably important to counter the heat loss to the jig and/or backing plate. In this study, three different backing-plate materials—cordierite ceramic, titanium alloy, and copper alloy—were used to evaluate the effect of heat loss on weldability in the μ-FSW process. One millimeter thick AA6061-T6 and AA5052-H32 dissimilar aluminum alloy plates were micro-friction stir welded by a butt joint. The tensile test, hardness, and microstructure of the welded joints using a tool rotational speed of 9000 rpm, a welding speed of 300 mm/min, and a tool tilting angle of 0° were evaluated. The heat loss was highly dependent on the thermal conductivity of the backing plate material, resulting in variations in the tensile strength and hardness distribution of the joints prepared using different backing plates. Consequently, the cordierite backing plate exhibited the highest tensile strength of 222.63 MPa and an elongation of 10.37%, corresponding to 86.7% and 58.4%, respectively, of those of the AA5052-H32 base metal.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

Parameters optimization in FSW of polypropylene based on RSM

2015 ◽  
Vol 11 (1) ◽  
pp. 32-42 ◽  
Author(s):  
K Panneerselvam ◽  
Kasirajan Lenin
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Optimization Techniques ◽  
Parameters Optimization ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Output Characteristics ◽  
Tool Pin

Purpose – The purpose of this paper is to weld polypropylene (PP) material by friction stir welding (FSW) process. The input process parameters considered were: tool pin profile, feed rate and tool rotational speed and the process output characteristics were tensile strength, Shore-D hardness, Rockwell hardness, Izod strength, Charpy strength and nugget area. Design/methodology/approach – Optimization of process parameters were carried out based on response surface methodology (RSM) and significant parameters were obtained by performing analysis of variance (ANOVA). Findings – The optimized results were the threaded pin profile for feed of 60 mm/min and tool rotational speed of 1,500 rpm. A confirmation test was carried out to verify the optimized results. Originality/value – In this paper, the process parameters were optimized based on RSM. This is newly adopted optimization techniques in the FSW process of PP materials and also it gives better results.

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.

Optimization of process parameters for friction stir welding of joining A6061 and A6082 alloys by Taguchi method

2012 ◽  
Vol 227 (6) ◽  
pp. 1150-1163 ◽  
Author(s):  
Sanjay Kumar ◽  
Sudhir Kumar ◽  
Ajay Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Experimental Tests ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Optimization Of Process Parameters ◽  
Tool Pin

The friction stir welding is a pioneering solid-state metal joining technique for producing high-quality joints in materials. In this article, Taguchi approach is applied to analyze the optimal process parameters for optimum tensile strength and hardness of welded dissimilar A6061 and A6082 alloys. An orthogonal array of L9 is implemented and the analysis of variance is employed to investigate the importance of parameters on responses. The experimental tests, conducted according to combination of rotational speed, tool tilt and types of tool pin profile parameters. The results indicate that the rotational speed is most significant process parameter that has the highest influence on tensile strength and hardness, followed by tool pin profile and tool tilt. The optimum results verified by conducting confirmation experiments. The predicted optimal value of tensile strength and hardness of dissimilar joints produced by friction stir welding are 267.74 MPa and 80.55 HRB, respectively.

Parametric optimization of friction stir welding process parameters of dissimilar welded joints using grey relational analysis and desirability function approach

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bhanodaya Kiran Babu Nadikudi
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Tilt Angle ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational

Purpose The main purpose of the present work is to study the multi response optimization of dissimilar friction stir welding (FSW) process parameters using Taguchi-based grey relational analysis and desirability function approach (DFA). Design/methodology/approach The welded sheets were fabricated as per Taguchi orthogonal array design. The effects of tool rotational speed, transverse speed and tool tilt angle process parameters on ultimate tensile strength and hardness were analyzed using grey relational analysis, and DFA and optimum parameters combination was determined. Findings The tensile strength and hardness values were evaluated from the welded joints. The optimum values of process parameters were estimated through grey relational analysis and DFA methods. Similar kind of optimum levels of process parameters were obtained through two optimization approaches as tool rotational speed of 1150 rpm, transverse speed of 24 mm/min and tool tilt angle of 2° are the best process parameters combination for maximizing both the tensile strength and hardness. Through these studies, it was confirmed that grey relational analysis and DFA methods can be used to find the multi response optimum values of FSW process parameters. Research limitations/implications In the present study, the FSW is performed with L9 orthogonal array design with three process parameters such as tool rotational speed, transverse speed and tilt angle and three levels. Practical implications Aluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. Originality/value Very limited work had been carried out on multi objective optimization techniques such as grey relational analysis and DFA on friction stir welded joints made with dissimilar aluminium alloys sheets.

Effect of Friction Stir Welding Process Parameters on Temperature Profile and Tensile Strength of Dissimilar Aluminum Alloys

2015 ◽  
Vol 813-814 ◽  
pp. 425-430
Author(s):  
Saurabh Kumar Gupta ◽  
K.N. Pandey ◽  
Rajneesh Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Temperature Profile ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Peak Temperature ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

The aim of this research is to study the effect of Friction Stir Welding (FSW) process parameters such as tool rotational speed and welding speed on temperature distribution and tensile strength of dissimilar AA5083-O and AA6063-T6 joint welded by FSW. Peak temperature at retreating side was observed lower as compared to advancing side for each experiment. Peak temperature decreases with decreasing the tool rotational speed but vice versa with welding speed. ANOVA indicated that the temperature profile was strongly dependent on the tool rotation speed than the welding speed and it also showed that welding speed is the main process parameter that has highest effect on tensile strength of welded joint.

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