Optimization of Process Parameters during Friction Stir Welding of Dissimilar Aluminium Alloys (AA 5083 & AA 6061) Using Taguchi L9 Orthogonal Array

2014 ◽  
Vol 592-594 ◽  
pp. 630-635 ◽  
Author(s):  
S. Ramesh Babu ◽  
P. Karthik ◽  
S. Karthik ◽  
S. Arun Kumar ◽  
Joel Marris
Keyword(s):  
Friction Stir Welding ◽  
Orthogonal Array ◽  
Welding Process ◽  
Weld Strength ◽  
Welding Parameters ◽  
Array Analysis ◽  
Friction Stir ◽  
Optimum Parameters ◽  
Optimization Of Process Parameters ◽  
Tool Profiles

In the present study AA5083 and AA6061 were welded using friction stir welding process by controlling the various welding parameters viz. rotational speed, welding speed and Tool axial force for two different tool profiles. Aluminum alloys 5083 and 6061 have similar properties and they both are widely used in marine industries and other transportation industries. In this work the effect of various parameters on the mechanical properties viz. tensile strength and impact strength were studied. In this study the Taguchi approach was used as a design of experiment to set optimum parameters. The experiments were done using Taguchi’s L9 orthogonal array. Analysis of variance test was also performed to obtain the effect of the parameters on the weld strength. Both DOE and ANOVA were performed using MINITAB software.

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 Friction stir welding of Aluminium matrix composites – A Review

2018 ◽  
Vol 144 ◽  
pp. 03002 ◽  
Author(s):  
Prabhu Subramanya ◽  
Murthy Amar ◽  
Shettigar Arun ◽  
Herbert Mervin ◽  
Rao Shrikantha
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Fusion Welding ◽  
Aluminium Matrix ◽  
Future Research ◽  
Matrix Composites ◽  
Aluminium Matrix Composites ◽  
Friction Stir ◽  
Tool Profiles ◽  
Welding Technique

Friction stir welding (FSW) is established as one of the prominent welding techniques to join aluminium matrix composites (AMCs). It is a solid state welding process, takes place well below the melting temperature of the material, eliminates the detrimental effects of conventional fusion welding process. Although the process is capable to join AMCs, challenges are still open that need to be fulfill to widen its applications. This paper gives the outline of the friction stir welding technique used to join AMCs. Effect of process variables on the microstructure and mechanical properties of the joints, behavior of reinforcing materials during welding, effect of tool profiles on the joint strength are discussed in detail. Few improvements and direction for future research are also proposed.

Process Parameter Optimization of Friction Crush Welding (FCW) of AISI 304 Stainless Steel

2017 ◽  
Author(s):  
Gurinder Singh Brar ◽  
Manpreet Singh ◽  
Ajay Singh Jamwal
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Pressure Vessels ◽  
304 Stainless Steel ◽  
Welding Parameters ◽  
Work Piece ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Friction Stir

AISI 304 stainless steel is one of the grades of steel widely used in engineering applications particularly in chemical equipments, food processing, pressure vessels and paper industry. Friction crush welding (FCW) is type of friction welding, where there is a relative motion between the tool and work-piece. In FCW process, the edges of the work-piece to be joined are prepared with flanged edges and then placed against each other. A non-consumable friction disc tool will transverse with a constant feed rate along the edges of the work-piece, which leads to welding. The joint is formed by the action of crushing a certain amount of additional flanged material into the gap formed by the contacting material. The novelty of present work is that FCW removes the limitations of friction stir welding and Steel work pieces can be economically welded by FCW. Taguchi method of Design of Experiments (DOE) is used to find optimal process parameters of Friction Crush Welding (FCW). A L9 Orthogonal Array, Signal to Noise ratio (S/N) and Analysis of Variance are applied to analyze the effect of welding parameters (welding speed, RPM, tool profile) on the weld properties like bond strength. Grain refinement takes place in friction crush welding as is seen in friction stir welding. Friction crush welding process also has added advantage in reducing distortion and residual stresses.

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.

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

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.

Effect of Strain Hardening on the Joint Efficiency of an Al-Mg-Sc-Zr Alloy Subjected to Friction Stir Welding

2014 ◽  
Vol 922 ◽  
pp. 463-468
Author(s):  
Sergey Malopheyev ◽  
Vladislav Kulitskiy ◽  
Sergey Mironov ◽  
Daria Zhemchuzhnikova ◽  
Rustam Kaibyshev
Keyword(s):  
Friction Stir Welding ◽  
Strain Hardening ◽  
Initial Conditions ◽  
Welding Process ◽  
Weld Strength ◽  
Friction Stir ◽  
Joint Efficiency ◽  
Cold Rolled ◽  
Cold Worked ◽  
Hot Rolled

The microstructure and mechanical properties of friction stir welded Al-5.4Mg-0.2Sc-0.1Zr alloy were studied. Defect-free welds were produced in hot extruded, hot rolled and cold rolled initial conditions. Friction stir welding led to the formation of ultrafine-grained structure in stir zone that contributes to overall strengthening. Coherent Al3(Sc,Zr) dispersoids retain partially during welding process that provides a joint efficiency close to 100% in the hot extruded and hot rolled materials. In the cold-rolled state the joint efficiency was found to be only 64%. The relatively low weld strength of the cold rolled material was attributed to the elimination of strain hardening due to the formation of recrystallized structure. It was shown that full strength weld can be achieved in semi-finished products of Al-Mg-Sc alloys in cold-worked and stabilized states being equal to H323 and H341 tempering by friction stir welding.

Effect of welding parameters on mechanical properties and microstructure of friction stir welded brass joints

2018 ◽  
Vol 106 (6) ◽  
pp. 606 ◽  
Author(s):  
İnan Geçmen ◽  
Zarif Çatalgöl ◽  
Mustafa Kemal Bilici
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Stir Zone ◽  
Weld Strength ◽  
Welding Parameters ◽  
Feed Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

Friction stir welding is a method developed for the welding of high-alloy aluminum materials which are difficult to combine with conventional welding methods. Friction stir welding of MS 63 (brass) plates used different tools (tapered cylindrical, tapered threaded cylindrical), tool rotational speeds (1040, 1500, 2080 rpm) and traverse speeds (30,45,75,113 mm.min−1). Tensile, bending, radiography and microstructure tests were carried out to determine the mechanical properties of brass plates joined by friction stir welding technique. Microstructure characterization studies were based on optical microscope and SEM analysis techniques. In addition, after joining operations, radiographs were taken to see the internal structure failure. Brass sheets were successfully joined to the forehead in the macrostructure study. In the evaluation of the microstructure, it was determined that there were four regions of base metal, thermomechanically affected zone (TMEB), heat-affected zone (HAZ) and stir zone. In both welding tools, the weld strength increased with increasing tool rotation speed. The particles in the stir zone are reduced by increasing of the tool rotation speed. Given the strength and % elongation values, the highest weld strength was achieved with tapered pin tool with a tool rotation speed of 1040 rpm and a tool feed speed of 113 min−1.

scholarly journals Force feedback-based quality monitoring of the friction stir welding process utilizing an analytic algorithm

2020 ◽  
Author(s):  
P. Rabe ◽  
A. Schiebahn ◽  
U. Reisgen
Keyword(s):  
Friction Stir Welding ◽  
Monitoring System ◽  
Force Feedback ◽  
Weld Seam ◽  
Position Control ◽  
Welding Process ◽  
Quality Monitoring ◽  
Welding Parameters ◽  
Process Data ◽  
Friction Stir

AbstractThe friction stir welding (FSW) process is known as a solid-state welding process, comparatively stable against external influences. Therefore, the process is commonly used with fixed welding parameters, utilizing axial force control or position control strategies. External and internal process disturbances introduced by workpiece, gap tolerance, tool wear, or machine/tool inadequacies are rarely monitored, and conclusions about the weld seam quality, based on the recorded process data, are not drawn. This paper describes an advancement, improving on research into the correlation of process force feedback events or gradual force changes and the resulting weld seam characteristics. Analyzing the correlation between examined weld sections and high-resolution rate force data, a quality monitoring system based on an analytic algorithm is described. The monitoring system is able to accurately distinguish sound welds from such with internal (void) and external (flash) defects.

Friction Stir Welding of Mg and Al Alloys

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.

Multi Response Optimization of Process Parameters using Taguchi based Grey Relational Method in FSW of AZ91B Magnesium Alloy

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
M.A. Unnikrishnan ◽  
J. Edwin Raja Dhas
Keyword(s):  
Tensile Strength ◽  
Magnesium Alloy ◽  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Welding Process ◽  
Welding Parameters ◽  
Friction Stir ◽  
Relational Analysis ◽  
Optimization Of Process Parameters ◽  
Grey Relational

In this paper, the Taguchi method and grey relational analysis have been used to evaluate the weldability of AZ91B Magnesium alloy by friction stir welding process. Experiments were conducted using the L9 Taguchi design considering an orthogonal array consist of 3 factors and 3 levels. The rotational speed, transverse speed and angle of tilt of the tool are selected as welding parameters. Analysis of variance (ANOVA) is used to analyze the influence of the welding parameters on the responses namely, ultimate tensile strength (UTS) and hardness. The analysis results revealed that the transverse speed is the predominant parameter affecting tensile strength, hardness and quality of the weld. Confirmation test results showed that the Taguchi method coupled with grey relational analysis is very successful in the optimization of welding parameters for maximum strength and hardness in the FSW of AZ91B Magnesium alloy.

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