Taguchi Optimization of Process Parameters in Friction Stir Spot Welding of AA5754 and AA2024 Alloys

2014 ◽  
Vol 1016 ◽  
pp. 161-166 ◽  
Author(s):  
Y. Bozkurt ◽  
Mustafa Kemal Bilici
Keyword(s):  
Spot Welding ◽  
Shear Fracture ◽  
Signal To Noise Ratio ◽  
Statistical Design ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameters ◽  
Taguchi Optimization ◽  
Friction Stir ◽  
Lap Shear

The feasibility of friction stir spot welding was studied on AA5754-H22 and AA2024-T3 aluminum alloys which have widespread applications in aircraft and automotive industries. The quality of the joint was evaluated by examining the characteristics of the joint as a result of lap-shear fracture load. Taguchi approach of the parameter design was used as a statistical design of experiment technique to set the optimal welding parameters. The experiments were arranged by using Taguchi’s L9 orthogonal array. The signal-to-noise ratio and the analysis of variance were utilized to obtain the influence of the friction stir spot welding parameters on the lap-shear fracture load. Finally, the results were confirmed by further experiments.

scholarly journals Spot Welding of 6061 Aluminum Alloy by Friction Stir Spot Welding Process

2017 ◽  
Vol 7 (3) ◽  
pp. 1629-1632 ◽  
Author(s):  
M. A. Tashkandi ◽  
J. A. Al-jarrah ◽  
M. Ibrahim
Keyword(s):  
Welded Joints ◽  
Spot Welding ◽  
Shear Fracture ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameters ◽  
Friction Stir ◽  
Pull Out ◽  
Lap Shear

This study was focused on the effect of welding parameters on the lap-shear fracture load of the welded joints prepared by friction stir spot welding. Four different weld parameters were analyzed: rotational speed, dwell time, pin length and shoulder size of the welding tool. It was found that the lap-shear fracture load increases with an increase of the welding parameters to a limited value and decreases with further increase. The strong welded joints failed under nugget-pull out fracture.

scholarly journals Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Metals ◽  
2018 ◽  
Vol 8 (11) ◽  
pp. 922 ◽  
Author(s):  
Xingwen Zhou ◽  
Yuhua Chen ◽  
Shuhan Li ◽  
Yongde Huang ◽  
Kun Hao ◽  
...  
Keyword(s):  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Stir Zone ◽  
Welding Parameters ◽  
Al Alloy ◽  
Ti Alloy ◽  
Friction Stir ◽  
2014 Al Alloy ◽  
Al Coating

Friction stir spot welding (FSSW) of Al to Ti alloys has broad applications in the aerospace and automobile industries, while its narrow joining area limits the improvement of mechanical properties of the joint. In the current study, an Al-coating was prepared on Ti6Al4V alloy by hot-dipping prior to joining, then a Zn interlayer was used during friction stir joining of as-coated Ti alloy to the 2014-Al alloy in a lap configuration to introduce a brazing zone out of the stir zone to increase the joining area. The microstructure of the joint was investigated, and the joint strength was compared with the traditional FSSW joint to confirm the advantages of this new process. Because of the increase of the joining area, the maximum fracture load of such joint is 110% higher than that of the traditional FSSW joint under the same welding parameters. The fracture load of these joints depends on the joining width, including the width of solid-state bonding region in stir zone and brazing region out of stir zone.

scholarly journals Effects of Dwell-Time and Plunge Speed during Micro Friction Stir Spot Welding on Mechanical Properties of Thin Aluminum A1100 Welds

2015 ◽  
Vol 758 ◽  
pp. 29-34 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
M.Dz. Habibullah ◽  
Z. Arvay ◽  
G. Kiswanto ◽  
...  
Keyword(s):  
Spot Welding ◽  
High Speed ◽  
Dwell Time ◽  
Shear Fracture ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameter ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes

Friction Stir Welding is a relatively new technique for joining metal. In some cases on aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and produces less distortion. The purpose of this study is to analyze the effect of high speed tool rotation on micro Friction Stir Spot Welding (μFSSW) to the shear fracture load of the welds. Response Surface Methods was used to analyze μFSSW parameters with the response. The welding material was Aluminum A1100, with thickness of 0.4 mm. The tool was made of HSS material which was shaped by micro grinding process. Tool shoulder diameter is 4 mm, and the pin diameter 1.5 mm with length of pin is 0.6 mm. The spindle speed is fixed at 33,000 rpm. The parameters that varied were the plunge speed (2 mm/min, 3 mm/min, 4 mm/min), and dwell time-1 (0 s, 2 s, 4 s) and variable of dwell time-2 (0 s, 2 s, 4 s). From the results of experiment and analysis, it is shown that the important welding parameter in high speed μFSSW process is dwell time-2.

scholarly journals Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

2019 ◽  
Vol 38 (2019) ◽  
pp. 69-75 ◽  
Author(s):  
Zhenlei Liu ◽  
Kang Yang ◽  
Dejun Yan
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Joint Strength ◽  
Shear Failure ◽  
Failure Load ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear

AbstractRefill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

Effects of High Speed Tool Rotation in Micro Friction Stir Spot Welding of Aluminum A1100

2014 ◽  
Vol 493 ◽  
pp. 739-742 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
Winarto
Keyword(s):  
Shear Strength ◽  
Spot Welding ◽  
High Speed ◽  
Tool Material ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes ◽  
Tool Rotation

Technology of Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on Aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and less distortion. The purpose of this study is to analyze the parameters effect of high speed tool rotation onmicro Friction Stir Spot Welding(μFSSW) to theshear strengthof welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. The spindle speed was fixed at 30000 rpm. Tool shoulder diameter was 3 mm, and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of pin diameter (1.5 mm, 2.0 mm, and 2.5 mm), a variable ofplunge speed(2 mm/min, 4 mm/min, 6 mm/min), and the variable ofdwell time(2 seconds, 4 seconds, 6 seconds). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was theshear strength.Response Surface Methods(RSM) was used to analyze μFSSW parameters with theshear strengthof welds. From the result of experiment and analysis, it is shown that the important welding parameters in high speed μFSSW process are pin diameter and plunge speed.

Relation between Friction Stir Spot Welding Parameters and Mechanical Properties of High Density Polyethylene/Glass Spheres Polymer Composites

2016 ◽  
Vol 860 ◽  
pp. 49-52 ◽  
Author(s):  
Munir Tasdemir ◽  
Mustafa Kemal Bilici ◽  
Mehmet Kurt
Keyword(s):  
Mechanical Properties ◽  
Polymer Composites ◽  
High Density Polyethylene ◽  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
High Density ◽  
Welding Parameters ◽  
Friction Stir ◽  
Glass Spheres ◽  
Welding Properties

In the present study, we attempt to use powder of glass spheres filler and reinforce material in HDPE to produce composite structure and then evaluate its mechanical properties to study the effect of welding parameters and filler content on mechanical properties of HDPE. The effect of welding parameters (tool rotational speed, the plunge depth and the dwell time) on friction stir spot welding properties of high density polyethylene/glass spheres (hollow) polymer composites sheets was studied.

Influence of Heating Friction Stir Spot Welding Process Parameters on Steel Aluminum Forming Quality

2018 ◽  
Vol 917 ◽  
pp. 246-251
Author(s):  
Kai Xu ◽  
Shu Quan Zhang
Keyword(s):  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Joint Line ◽  
Welding Parameters ◽  
Forming Quality ◽  
Rotating Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Pressure

A lap welding experiment of DP590 steel and 6061 aluminum plate is carried out by using Heating Friction Stir Spot Welding (HFSSW) to study the influence of welding parameters on the forming quality. The results show that a lap joint with better forming can be obtained for the dissimilar metal of steel and aluminum. Under the condition that the rotating speed of the stirring tool is 1000r/min, the penetration depth, 0.2mm, the dwell time, 90s, the welding pressure, 0.2Mp, and the flow rate of cooling air, 20L/min, the forming quality of the surface of the joint line is good & bright, and the exit hole is also smaller. The mechanism of heat production is revealed in the following: the main heat is produced by the friction between the stirring tool shoulder and the welded part & between the probe and the welded part as well as by the latent heat resulted from the plastic deformation of the material in joint line during welding.

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