Comparison of the Optimized Process Parameters of Double-Sided Friction Stir Welded Aluminium Alloy Joints Using Statistical and Evolutionary Techniques

2016 ◽  
Vol 852 ◽  
pp. 317-323 ◽  
Author(s):  
S. Vignesh ◽  
P. Dinesh Babu ◽  
C. Balamurugan ◽  
S. Martin Vinoth
Keyword(s):  
Response Surface Methodology ◽  
Evolutionary Algorithm ◽  
Response Surface ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Welding Process ◽  
Regression Equations ◽  
Friction Stir ◽  
Desirability Approach

One of the most innovative solid state welding techniques used in the aerospace, automotive, defence, rail and marine industries is Friction Stir Welding (FSW) process, as it is used for joining aluminium, copper and magnesium alloys. The weld quality is decided by the FSW process parameters such as rotational speed, welding speed and pin profile. A regression model was developed relating the welding input parameters (tool rotational speed, welding speed and pin profile) and the output response parameters (tensile strength, hardness and toughness) based on the experiments carried out with the help of Response Surface Methodology. The obtained regression equations were used in determining the optimal welding process parameters. A new method, Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) based on evolutionary algorithm has been used in the optimisation. The optimum results gathered from the desirability approach through Response Surface Methodology (RSM) were compared with those obtained through the evolutionary algorithm. The results show that the proposed evolutionary method is much effective, faster than the desirability approach discussed in the work.

scholarly journals Optimization of process parameters of friction stir welded AA 5083-O aluminum alloy using Response Surface Methodology

2015 ◽  
Vol 63 (4) ◽  
pp. 851-855 ◽  
Author(s):  
S. Jannet ◽  
P. Koshy Mathews ◽  
R. Raja
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Ultimate Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Strength Analysis ◽  
Aluminum Compound ◽  
Friction Stir

Abstract A methodology was exhibited to create the experimental model for assessing the Ultimate Tensile Strength of AA 5083-O aluminum compound which is broadly utilized as a part of boat building industry by Friction Stir Welding (FSW). FSW process parameters, such as: tool rotational speed, welding speed, and axial force were optimized for better results. FSW was completed considering three-component 3-level Box Behnekn Design. Response surface Methodology (RSM) was implemented to obtain the relationship between the FSW process parameters and ultimate Tensile Strength. Analysis of Variance (ANOVA) procedure was utilized to check the aptness of the created model. The FSW process parameters were additionally streamlined utilizing Response Surface Methodology (RSM) to augment tensile strength. The joint welded at a rotational speed of 1100 rpm, a welding speed of 75 mm/min and a pivotal energy of 2.5 t displays higher tensile strength compared with different joints in comparison with other joints.

Influence of Welding Process Parameters on Microstructure and Mechanical Properties of Friction Stir Welded Aluminium Matrix Composite

2016 ◽  
Vol 880 ◽  
pp. 50-53 ◽  
Author(s):  
Subramanya Prabhu ◽  
Arun Kumar Shettigar ◽  
Karthik Rao ◽  
Shrikantha Rao ◽  
Mervin Herbert
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Joint Strength ◽  
Welding Process ◽  
Aluminium Matrix ◽  
Friction Stir ◽  
Weld Region ◽  
Microstructure And Mechanical Properties

In this study, the effect of process parameters on microstructure and mechanical properties of friction stir welded aluminium matrix composites (AMC) have been explored. The results indicated that the recrystallized grain size at the bottom of the weld region is smaller than that at the top region due to difference in the heat transfer at the weld region. The joint strength of AMCs depends on proper selection of process parameters like tool rotational speed and welding speed. If process parameter values are beyond the optimal value, the joint strength decreases due to formation of defects. Maximum tensile strength is obtained for rotational speed of 1000 rpm and welding speed of 80mm/min.

Micro-hardness prediction of friction stir processed magnesium alloy via response surface methodology

2017 ◽  
Vol 13 (3) ◽  
pp. 377-390 ◽  
Author(s):  
Ahmed Naser ◽  
Basil Darras
Keyword(s):  
Response Surface Methodology ◽  
Magnesium Alloy ◽  
Response Surface ◽  
Process Parameters ◽  
Rotational Speed ◽  
Micro Hardness ◽  
Content Type ◽  
Friction Stir ◽  
Effective Use ◽  
Hardness Values

Purpose The purpose of this paper is to present a model to predict the micro-hardness of friction stir processed (FSPed) AZ31B magnesium alloy using response surface methodology (RSM). Another objective is to identify process parameters and through-thickness position which will give higher micro-hardness values. Moreover, the study aims at defining the factor that exhibits the most effect on the micro-hardness. Friction stir processing (FSP) machine can then be fed with the optimized parameters to achieve desirable properties. Design/methodology/approach An experimental setup was designed to conduct FSP. Several AZ31B magnesium samples were FSPed at different combinations of rotational and translational speeds. The micro-hardness of all the combinations of process parameters was measured at different through-thickness positions. This was followed by an investigation of the three factors on the resulting micro-hardness. RSM was then used to develop a model with three factors and three levels to predict the micro-hardness of FSPed AZ31 magnesium alloy within the covered range. The analyses of variance in addition to experimental verification were both used to validate the model. This was followed by an optimization of the response. Findings The model showed excellent capability of predicting the micro-hardness values as well as the optimum values of the three factors that would result in better micro-hardness. The model was able to capture the effects of rotational speed, translational speed, and through-thickness position. Results suggest that micro-hardness values were mostly sensitive to changes in tool rotational speed. Originality/value FSP is considered to be one of the advanced microstructural modification techniques which is capable of enhancing the mechanical properties of light-weight alloys. However, the lack of accurate models which are capable of predicting the resulted properties from process parameters hinders the widespread utilization of this technique. At the same time, RSM is considered as a vital branch of experimental design due to its ability to develop new processes and optimize their performance. Hence, the developed model is very beneficial and is meant to save time and experimental effort toward effective use of FSP to get the desired/optimum micro-hardness distribution.

scholarly journals Parametric Optimization of Butt Welded Polycarbonate using Response Surface Methodology

2021 ◽  
Vol 40 (1) ◽  
pp. 38-52
Author(s):  
Abid Imtiaz ◽  
Adnan Tariq ◽  
Ajaz Bashir Janjua ◽  
Fahad Sarfraz ◽  
Amar ul Hassan Khawaja
Keyword(s):  
Mechanical Properties ◽  
Response Surface Methodology ◽  
Solid State ◽  
Response Surface ◽  
Process Parameters ◽  
Base Material ◽  
Welding Process ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir

Friction Stir Welding (FSW) is a solid-state joining process for metals, non-metals and polymers. It is carried out with the help of a specially designed, non-consumable tool. The heat required, for creating a softened region at the faying surfaces, is generated by rotation of tool against the work piece material. Being a solid-state welding process, it offers several advantages like inducing minimum effect on the mechanical properties of base material, reduced shrinkage and distortion, no spatter or Ultra Violet (UV) radiations etc. However, developing a sound weld requires an appropriate combination of several process parameters e.g. the design of tool, its rotational and traversing speeds etc. To substantiate this aspect, an approach based on Response Surface Methodology (RSM) is presented during this paper that optimizes the combination of process parameters while investigating their effect on the mechanical properties of a friction stir welded butt joint configuration of Polycarbonate. To minimize the total number of combinations a Central Composite Rotatable Design (CCRD) is used with three factors and two levels. The results have shown that the butt joints fabricated at a traverse speed of 14 mm/min, rotational speed of 1700 RPM and with simple cylindrical conical tool geometry yielded the maximum ultimate tensile strength of 51.299 MPa.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

Comparison of response surface methodology with artificial neural network for prediction of the tensile properties of friction stir-processed surface composites

2021 ◽  
pp. 095440892110368
Author(s):  
Ravi Butola ◽  
Ranganath M. Singari ◽  
Qasim Murtaza ◽  
Lakshay Tyagi
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Tensile Strength ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Rotational Speed ◽  
Total Elongation ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Artificial Neural

In the present work, nanoboron carbide is integrated in the aluminum matrix using friction stir processing: by varying process parameters, that is, tool pin profile, tool rotational speed and tool traverse speed, based on Taguchi L16 design of experiment. A self-assembled monolayer is successfully developed on the substrate to homogeneously and uniformly distribute the reinforcement particles. Response surface methodology and artificial neural network models are developed using ultimate tensile strength and total elongation as responses. Percentage absolute error between the experimental and predicted values of ultimate tensile strength and total elongation for the response surface methodology model is 3.537 and 2.865, respectively, and for artificial neural network is 2.788 and 2.578, respectively. For both the developed models experimental and forecasted values are in close approximation. The artificial neural network model showed slightly better predictive capacity compared to the response surface methodology model. From the scanning electron microscopy micrograph, it is evident that throughout the matrix B4C reinforcement particles are well distributed also; with increasing tool rotational speed grain size decreases up to 1200 r/min; on further increasing the tool rotational speed particles starts clustering.

Multi-Performance Optimization in Friction Stir Welding of Aluminum Alloy Using Response Surface Methodology

2018 ◽  
pp. 240-263
Author(s):  
Rajat Gupta ◽  
Kamal Kumar ◽  
Neeraj Sharma
Keyword(s):  
Response Surface Methodology ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Response Surface ◽  
Process Parameters ◽  
Performance Optimization ◽  
Desirability Function ◽  
High Carbon Steel ◽  
Friction Stir ◽  
Tool Shoulder

This chapter presents the friction stir welding (FSW) of aluminum alloy AA-5083-O using vertical milling machine. In present FSW experimentation, effects of different process parameter namely tool rotation speed, welding speed, tool geometry, and tool shoulder diameter have been determined on welding quality of two pieces of AA-5083-O using response surface methodology (RSM). The optimal sets of process parameters have been determined for weld quality characteristics namely tensile strength (UTS) and percentage elongation (%EL). In present experimentations, a specially designed tool made of high carbon steel with different shoulder diameters (15mm, 17.5mm, and 20 mm) having constant pin length (6 mm) were used for FSW of two pieces of aluminum alloy. The ANOVA and pooled ANOVA were used to study the effect of FSW parameters on UTS and %EL. Multi response optimization has been carried out using desirability function in conjunction with RSM to obtain the optimal setting of process parameters for higher UTS and lower %EL.

scholarly journals Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1480
Author(s):  
Assefa Asmare ◽  
Raheem Al-Sabur ◽  
Eyob Messele
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Weight Ratio ◽  
Welding Process ◽  
Quality Criteria ◽  
Alloy Sheet ◽  
Friction Stir ◽  
Weld Joints

The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

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