Optimization of Process Parameters for Friction Stir Welding of Dissimilar Aluminium Alloy AA6061 to AA5183 using TOPSIS Technique

Friction stir welding has proven to be the most promising solid state joining process. It can be used to get high weldability in joining of high strength aerospace aluminium alloys and other metallic alloys which used to be low with traditional fusion welding process. This paper emphasises on finding the optimum process parameter for friction stir welding of dissimilar aluminium alloy AA6061 to AA5183 using multi criteria decision making method (MCDM). Friction stir welding was done at different tool rotational speed and transverse velocity and mechanical properties such as tensile strength, percentage elongation and hardness were studied for each weld specimen. Finally optimization was done using TOPSIS (Techniqueof Ordered Preference by Similarity to Ideal Solution). The result revealed that the tool rotational speed of 1200 rpm and welding speed of 80mm/min are the optimum welding parameters

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Comparative assessment on weldability of Al 6061 to polycarbonate for dissimilar sheets placement in friction stir lap welding using sensor signals

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

10.1177/09544062211042663 ◽

2021 ◽

pp. 095440622110426

Author(s):

Nisith Goswami ◽

Kamal Pal

Keyword(s):

Friction Stir Welding ◽

Aluminium Alloy ◽

Rotational Speed ◽

Weight Ratio ◽

Weld Interface ◽

Fusion Welding ◽

Tool Rotational Speed ◽

Friction Stir ◽

Joint Efficiency ◽

Welding Processes

The thermoplastic polymers and precipitation hardened aluminium alloys are highly popular in the aerospace and automobile sectors as a replacement of metallic materials to improve the strength to weight ratio. Thus, the unlike aluminium alloy to polycarbonate assembled structures are often necessary for which mechanical fastening and adhesive bonding are the primary methods for joining as fusion welding processes are inadequate. However, the dissimilar joint efficiency is found to be less. Thus, the ultrasonic and friction welding processes are developed. The friction stir welding is one such advanced material stirring technique without any melting of base materials. The present work addresses metallic aluminium (Al6061) to polycarbonate sheet materials joining using friction stir welding in overlap configuration using tapered H13 tool steel. The thrust force with associated tool stirring torque has been acquired in real time during plunging followed by welding phase. The weld bead profile with respective force-torque signals was analysed for the process monitoring. The tensile test has been carried out on the lap welds. The weld interface of the unlike sheets have also been scrutinised. Initially, the aluminium sheet was partially overlapped on polycarbonate for the parametric study. The highest joint efficiency was found to be 40.2% at 1400 rpm tool rotational speed and 75 mm/min traverse speed due to improper material mixing at the weld interface. Therefore, the feasibility of the process have been tested by placing thermoplastic polycarbonate over aluminium alloy through which the joint efficiency was further improved (48.57%) at comparatively low tool rotational speed (1100 rpm) with lower welding speed (55 mm/min) as the minute metallic particles uniformly mixed with melted and solidified polycarbonate due to more uniform torque in the welding phase. The tool stirring torque and axial thrust was found to be higher in this overlap position.

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Influence of tool rotational speed on mechanical properties of aluminium alloy AA 7075-T6 during friction stir welding process

Advances in Materials and Processing Technologies ◽

10.1080/2374068x.2021.1953928 ◽

2021 ◽

pp. 1-13

Author(s):

Akash Sharma ◽

Vijay Kumar Dwivedi

Keyword(s):

Mechanical Properties ◽

Friction Stir Welding ◽

Aluminium Alloy ◽

Rotational Speed ◽

Welding Process ◽

Tool Rotational Speed ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Aa 7075

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Mechanical Property of Friction Stir Welded Retardant Magnesium Alloy Joint

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.295-297.1929 ◽

2011 ◽

Vol 295-297 ◽

pp. 1929-1932

Author(s):

Yi Min Tu ◽

Ran Feng Qiu ◽

Hong Xin Shi ◽

Xin Zhang ◽

Ke Ke Zhang

Keyword(s):

Mechanical Properties ◽

Mechanical Property ◽

Friction Stir Welding ◽

Magnesium Alloy ◽

Welding Speed ◽

Rotational Speed ◽

Maximum Strength ◽

Welding Parameters ◽

Tool Rotational Speed ◽

Friction Stir

In order to obtain better understanding of the friction stir weldability of the magnesium alloy and provide some foundational information for improving mechanical properties of retardant magnesium alloy joints. A retardant magnesium alloy was weld using the method of friction stir welding. The influence of welding parameters on the strength of the joint was investigated. The maximum strength of 230 MPa was obtained from the joint welded at the tool rotational speed of 1000 r/min and welding speed of 750 mm/min.

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Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.857.228 ◽

2016 ◽

Vol 857 ◽

pp. 228-231

Author(s):

Ho Sung Lee ◽

Ye Rim Lee ◽

Kyung Ju Min

Keyword(s):

Mechanical Properties ◽

Friction Stir Welding ◽

Space Shuttle ◽

Welding Process ◽

High Strength ◽

Fusion Welding ◽

Welding Parameters ◽

Friction Stir ◽

Mechanical And Microstructural Properties ◽

Tool Rotation

Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

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Optimization of Friction Stir Welding Process Parameters to Join Al 5052 and Al 6061 Alloy Plates Using Grey-Taguchi Technique

Volume 1: Processes ◽

10.1115/msec2017-2605 ◽

2017 ◽

Author(s):

R. Sandeep ◽

D. Sudhakara ◽

G. Prasanthi

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Welding Process ◽

Dissimilar Materials ◽

Fusion Welding ◽

Optimum Process ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Grey Analysis ◽

Grey Taguchi

Friction stir welding (FSW) is a solid state welding process used for welding similar and dissimilar materials. The process is widely used because it does not have common problems such as solidification and liquefaction cracking associated with the fusion welding techniques. The objective of the present research is to find the best combination of friction stir welding process parameters to join aluminium 5052 and 6061 alloy materials. The combination of process parameters is helpful to improve ultimate tensile strength, yield strength, percentage of elongation and hardness of welded joint. To achieve the research objective taguchi based grey analysis was used. The optimum process parameters were found be at rotational speed is 1400 rpm, transverse speed of 100 mm/min and axial force is at 11 KN.

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Friction Stir Welding of Mg and Al Alloys

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.875-877.1477 ◽

2014 ◽

Vol 875-877 ◽

pp. 1477-1482

Author(s):

Tomáš Kupec ◽

Ivana Hlaváčová ◽

Milan Turňa

Keyword(s):

Friction Stir Welding ◽

Slovak Republic ◽

Welding Process ◽

Hardness Measurement ◽

Fusion Welding ◽

Welding Parameters ◽

Power Sources ◽

Friction Stir ◽

Alloy Type ◽

Equipment Type

The work deals with welding of aluminium alloy typeAlMg4,5Mn and magnesium alloy type AZ 31 in solid state by FSW (Friction Stir Welding) process. Experiments were performed in cooperation with VÚZ PI SR (Welding Research Institute Industrial Institute of Slovak Republic) Bratislava, which has available a new installed equipment type FSW LM 060 manufactured in China. Welding parameters and conditions were proposed and approved. Quality of fabricated joints was assessed by optical microscopy, micro hardness measurement and radiographic test - RT. It was supposed that optimisation of welding parameters would allow to fabricate the joints of acceptable quality that might compete to technologies of fusion welding, including welding with concentrated power sources.

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Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

International Journal of Advanced Information and Communication Technology ◽

10.46532//ijaict-2020015 ◽

2020 ◽

pp. 64-68

Author(s):

Anganan K ◽

Narendran RJ ◽

Naveen Prabhu N ◽

Rahul Varma R ◽

Sivasubramaniyam R

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Aluminum Alloys ◽

Welding Speed ◽

Rotational Speed ◽

Copper Alloys ◽

Welding Parameters ◽

Tool Rotational Speed ◽

Friction Stir ◽

Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

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Establishing optimal friction stir welding parameters for AA2219-T87 Al-alloy using comprehensive RSM and GA approach

Engineering Research Express ◽

10.1088/2631-8695/ac41b5 ◽

2021 ◽

Author(s):

Boddu Rajnaveen ◽

Govada Rambabu ◽

Kollabothina Prakash ◽

Kotipalli Srinivasa Rao

Keyword(s):

Friction Stir Welding ◽

Aluminium Alloy ◽

Welding Process ◽

Welding Parameter ◽

Welding Parameters ◽

Al Alloy ◽

Regression Equations ◽

Corrosion Properties ◽

Friction Stir ◽

Aa2219 Alloy

Abstract AA2219-T87 aluminium alloy has been used in aerospace applications because of its high strength, low density and resistance to corrosion. The copper in the alloy improves the hardness and lowers melting point, which makes two sections easily joined with a process called friction stir welding of aluminium alloy. In the present work, heat-treated AA2219 alloy was butt welded by solid-state friction stir welding process. This work aims to develop a suitable combination of welding parameters for producing defect-free weld joints of AA2219 alloy to improve tensile and corrosion properties. The most influencing control parameter for optimising the friction stir welding responses was determined using sophisticated design of experiments (DOE) techniques. Ultimate tensile strength and corrosion resistance are observed as responses in this study. To achieve the desired weld responses, a three-factor, three-level Box-behneken design was used. Analysis of Variance (ANOVA) was carried out to examine the interaction effect and significant welding parameter to set the optimal level of welding conditions. Multi-response regression equations have been developed using response surface methodology (RSM) to estimate the output characteristics of weld. The Genetic algorithm (GA) was used to optimise the predicted mathematical model under given optimization constraints. The results shown that the optimum responses are obtained at input factors rotational speed 300 rpm, welding speed 80 mm/min, and axial force of 10kN.

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Correlative Analysis Between Tensile Properties and Tool Rotational Speeds of Friction Stir Welded Similar Aluminium Alloy Joints

International Journal of Surface Engineering and Interdisciplinary Materials Science ◽

10.4018/ijseims.2021070104 ◽

2021 ◽

Vol 9 (2) ◽

pp. 58-78

Author(s):

Velaphi Msomi ◽

Busiswa Tracey Jantjies

Keyword(s):

Friction Stir Welding ◽

Tensile Properties ◽

Rotational Speed ◽

Critical Parameter ◽

Welding Parameters ◽

Tool Rotational Speed ◽

Friction Stir ◽

Correlative Analysis ◽

Fsw Parameters ◽

The Impact

Friction stir welding (FSW) is considered as the new joining technique which does not involve fumes like any traditional joining techniques. The attainment of good weld depends on proper combination of FSW parameters, and this combination varies with the materials that are being welded. The tool rotational speed is known as the most critical parameter towards the generation of heat required to produce the weld in friction stir welding. This parameter plays an important role in restructuring the stir zone. The variation of this parameter may yield certain results which are dependent on the type of materials being welded. This paper reports on the impact of the rotational speed variation on the tensile properties of AA6082-T6 joints. The rotational speed was varied while keeping all the other welding parameters constant. The analysis was performed comparatively on the specimens that were sampled from different locations of the joint. The joints produced through the rotational speed of 600 rpm showed good tensile properties compared to joints produced through other rotational speeds.

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