Modeling of Friction Stir Welding of AL7075 Using Neural Networks

2012 ◽  
Vol 3 (1) ◽  
pp. 66-79 ◽  
Author(s):  
Sasidhar Muttineni ◽  
Pandu R. Vundavilli
Keyword(s):  
Neural Network ◽  
Mechanical Properties ◽  
Neural Networks ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
High Speed ◽  
Welding Process ◽  
High Speed Steel ◽  
Operating Conditions ◽  
Friction Stir

Friction stir welding (FSW) is a solid state welding process, which is used for the welding of aluminum alloys. It is important to note that the mechanical properties of the FSW process depends on various process parameters, such as spindle speed, feed rate and shoulder depth. Two different tool materials, such as High speed steel (HSS) and H13 are considered for the welding of Al 7075. The present paper deals with the modeling of FSW process using neural networks. A three layered feed forward neural network (NN) has been used to model the FSW of aluminum alloys. It is important to note that the connection weights and bias values of the NN are optimized with the help of a binary coded genetic algorithm (GA). The training of the NN with the help of GA is a time consuming process. Hence, offline training has been provided to optimize the connection weights and bias values of the neural network. Once, the training is over, the GA trained neural network will be used for online prediction of the mechanical properties of FSW process at different operating conditions.

scholarly journals Wear Inducing Phase Transformation of Plasma Transfer Arc Coated Tools during Friction Stir Welding with Al Alloy

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Kuan-Jen Chen ◽  
Fei-Yi Hung ◽  
Truan-Sheng Lui ◽  
Yong-Ren Shih
Keyword(s):  
Wear Resistance ◽  
Phase Transformation ◽  
Friction Stir Welding ◽  
High Speed ◽  
Phase Transfer ◽  
Welding Process ◽  
High Speed Steel ◽  
Al Alloy ◽  
Transfer Layer ◽  
Friction Stir

The friction stir welding process (friction stir welding/processing, FSW/FSP) has wear problems related to stirring tools. In this study, the plasma transfer arc (PTA) method was used with stellite 1 powders (Co-based) to coat on the head of a SKD61 stirring tool (SKD61-ST1) in order to investigate the wear performance and phase transformation of SKD61-ST1 after FSW. Under the same experimental parameters, the wear data were compared with the high-speed steel SKH51 (tempering material SKH51-T and annealed material SKH51-A) and tungsten-carbide cobalt (TCC). Results showed the PTA coating was a γ-Co solidification matrix with M7C3 and M23C6 carbides. After FSW, the wear resistance of SKD61-ST1 was better than that of SKH51-A and SKH51-T and lower than that of TCC. The SKD61-ST1, SKH51-A, and SKH51-T stirring tools exhibited sliding wear after FSP, where the pin and shoulder of the stirring tool formed a phase transfer layer on the surface, and the peeling of the phase transfer layer caused wear weight loss. The main phase of the phase transfer layer of the SKD61-ST1 tool was Al9Co2. The affinity and adhesion energy of the Co-Al phase was lower than that of Fe-Al phase, and the phase transfer layer of the SKD61-ST1 tool was thinner and had lower coverage, thereby increasing the wear resistance of the SKD61-ST1 stirring tools during FSW.

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.

Microstructure and Mechanical Properties of Friction Stir Welding Joint of Pure Copper

2011 ◽  
Vol 418-420 ◽  
pp. 1520-1523
Author(s):  
Yong Zhao ◽  
You Li Ye ◽  
Keng Yan ◽  
Li Long Zhou
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
High Speed ◽  
Bonding Temperature ◽  
Pure Copper ◽  
High Speed Steel ◽  
Weld Nugget ◽  
Nugget Zone ◽  
Friction Stir ◽  
Welding Joint

Microstructures and mechanical properties of pure copper weld joints are discussed under different parameters of friction stir welding. The results reveal that it is conducive to the formation of compact joint in friction stir welding by applying high speed steel tool with high anti-bonding temperature. The friction stir welding joint with compact and defect-free microstructure could be obtained when the tool rotation rate is 1250- 1650 r/min and the tool traverse speed is 20-50 mm/min. Intensively plastic deformation occurs in the soften materials of the weld nugget zone and numerous crystal particles are broken under the influence of tool stirring. The microstructure of weld nugget zone is composed of tiny isometric crystals, which is due to the dynamic recrystallization of broken crystal particles. The structure of thermo-mechanical affected zone on both sides is asymmetric. Obvious boundary of the thermo affected zone could be seen on the advancing side, and the plastic streamline is apparent.

A Survey of the Parameters of the Friction Stir Welding Process of Aluminum Alloys 6xxx Series

2021 ◽  
Vol 9 (1) ◽  
pp. 51-60
Author(s):  
Meshal Essa ◽  
Fahad Salem Alhajri
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Process ◽  
Literature Survey ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Welding Processes ◽  
6Xxx Series

Friction stir welding is a modern innovation in the welding processes technology, there are ‎several ways in which this technology has to be investigated in order to refine and make it ‎economically responsible. Aluminum alloys have strong mechanical properties when they are ‎welded by using the Friction Stir welding. Therefore, certain parameters of the welding ‎process need to be examined to achieve the required mechanical properties. In this project, a ‎literature survey has been performed about the friction stir welding process and its parameters ‎for 6xxx series aluminum alloys‎.  

scholarly journals The Effects of In-Process Cooling during Friction Stir Welding of 7475 Aluminium Alloy

2021 ◽  
Vol 50 (9) ◽  
pp. 2743-2754
Author(s):  
Ashish Jacob ◽  
Sachin Maheshwari ◽  
Arshad Noor Siddiquee ◽  
Abdulrahman Al-Ahmari ◽  
Mustufa Haider Abidi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welded Joints ◽  
Positive Impact ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Cooling Conditions ◽  
Zero Degree ◽  
Welding Technique

Certain age hardenable alloys such as AA7475 cannot be joined with perfection using fusion welding techniques. This requires non-conventional welding technique such as friction stir welding process to join these ‘difficult to weld’ alloys. In this study, three different cooling conditions i.e. cryogenic, sub-zero, and zero-degree Celsius temperature conditions have been analyzed to understand its impact on the welding process. In-process cooling was found to behave effectively and also enhanced the mechanical properties of the welded joints. A stable microstructure was clearly seen in the images observed under the metallurgical microscope. The weld efficiencies were found to be good in each of the samples which are indicative of a strong metallic joint. The effective cooling conditions employed had an overall positive impact on the joint.

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