Impact of Tool Pin Geometry and Optimized Process Parameters on Mechanical Properties of Friction Stir Welded AZ80A Mg Alloy

2016 ◽  
Vol 866 ◽  
pp. 151-155 ◽  
Author(s):  
V. Jaiganesh ◽  
P.K. Nagarajan ◽  
P. Sevvel ◽  
J. Dhileep Kumar ◽  
S. Manivannan
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Feed Rate ◽  
Rotational Speed ◽  
Mg Alloy ◽  
Tool Rotational Speed ◽  
Pin Geometry ◽  
Az80a Mg Alloy ◽  
Parameter Values ◽  
Tool Pin

In this paper, the influence of optimized FSW process parameters namely tool rotational speed, feed rate, mechanical axial force and impact of tool pin geometry on the mechanical properties of AZ80A Mg alloy are experimentally investigated in a detailed manner. M35 grade High Speed Steel (HSS) tool with three different pin geometries namely straight cylindrical, threaded cylindrical and taper cylindrical was employed in this investigation. The joints obtained under these conditions are subjected to tensile tests as per ASTM (American Society for Testing and Materials) B557M – 10 standards and tensile fracture surfaces are examined using optical and Scanning Electron Microscope (SEM). The investigations proved that defect free sound joints with better mechanical properties are produced by taper cylindrical tool pin geometry under optimized process parameter values. It was experimentally found that the optimized FSW process parameter values namely 1.0 mm/min feed rate, 5 kN axial force, 1000 rpm of tool rotational speed along with a taper cylindrical pin profiled tool is preferable for FSW of AZ80A Mg alloy of 5mm thickness.Moreover, this experimental work revealed us that the taper cylindrical pin profiled tool fabricated sound, defect free welded joints along with better & improved mechanical properties when compared with other two pin profiles.

Parameters optimization in FSW of polypropylene based on RSM

2015 ◽  
Vol 11 (1) ◽  
pp. 32-42 ◽  
Author(s):  
K Panneerselvam ◽  
Kasirajan Lenin
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Optimization Techniques ◽  
Parameters Optimization ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Output Characteristics ◽  
Tool Pin

Purpose – The purpose of this paper is to weld polypropylene (PP) material by friction stir welding (FSW) process. The input process parameters considered were: tool pin profile, feed rate and tool rotational speed and the process output characteristics were tensile strength, Shore-D hardness, Rockwell hardness, Izod strength, Charpy strength and nugget area. Design/methodology/approach – Optimization of process parameters were carried out based on response surface methodology (RSM) and significant parameters were obtained by performing analysis of variance (ANOVA). Findings – The optimized results were the threaded pin profile for feed of 60 mm/min and tool rotational speed of 1,500 rpm. A confirmation test was carried out to verify the optimized results. Originality/value – In this paper, the process parameters were optimized based on RSM. This is newly adopted optimization techniques in the FSW process of PP materials and also it gives better results.

Effects of friction stir welding on corrosion and mechanical properties of AA6063 in sea water

2021 ◽  
pp. 095440622199554
Author(s):  
Laxmana Raju Salavaravu ◽  
Lingaraju Dumpala
Keyword(s):  
Mechanical Properties ◽  
Electron Microscope ◽  
Friction Stir Welding ◽  
Corrosion Rate ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

Submerged friction stir welding (FSW) is used to improve the weld zones mechanical properties in the present study. This research aims to obtain the optimized process parameters used to fabricate the AA6063 Submerged FSW joint. In the Submerged FSW process, the most important influential factors are tool rotational speed, traverse speed, and pin profile in a seawater environment. The different workpieces are friction stir welded while submerged in seawater at different tool rotational speeds, traverse speeds, and tool pin profiles such as square pin, cylindrical taper pin, and threaded pin. The produced weldments were tested for the mechanical properties of higher tensile strength, microhardness, corrosion rate, and the microstructure of weldments was characterized by using a scanning electron microscope, transmission electron microscope, and X-ray diffractometer. The corrosion rate is investigated by using an electrochemical analyzer by potential dynamic polarization open-circuit technique. For this investigation, The Taguchi method with the L9 orthogonal array design of experimentation is adopted. The maximum UTS was acquired in the weld joint fabricated with 1250 r/min of tool rotational speed, 45 mm/min traverse speed, and a square tool pin. The stirred zone is tested for microhardness. High hardness is achieved with high tool rotational speed and low traverse speed with a square tool pin profile. The corrosion rate is also decreased with high tool rotational speed, low traverse speed, and a square tool pin profile.

scholarly journals Experimental Identification of Optimized Process Parameters for FSW of AZ91C Mg Alloy Using Quadratic Regression Models

2020 ◽  
Vol 66 (12) ◽  
pp. 736-751
Author(s):  
Satheesh C ◽  
Sevvel P ◽  
Senthil Kumar R
Keyword(s):  
Mechanical Properties ◽  
Response Surface ◽  
Process Parameters ◽  
Regression Models ◽  
Mg Alloy ◽  
Regression Equations ◽  
Quadratic Regression ◽  
Input Process ◽  
Friction Stir ◽  
Pin Geometry

This experimental work aims to devise and establish quadratic regression equations, including various input criteria of a friction stir welding (FSW) technique to predict and determine the responses during the fabrication of AZ91C Mg alloy joints. The input process parameters taken into consideration include the traversing speed of the tool, the speed of rotation of the tool, its pin profile (geometry) and the axial force. A five-level, 4 four-factor composite design (of central nature) was applied, and response surface methodology (RSM) was used to formulate quadratic regression models, to develop 3D response surface charts, and to anticipate the responses for various mechanical properties. The generated quadratic mathematical model was tested and validated using the technique of analysis of variance. Validation experimental trial results outlined in the form of scatter diagrams revealed precedented coincidence with that of the generated models. The AZ91C Mg alloy joints obtained using the tool having taper cylindrical pin geometry employed at 1045 rpm, 1.5 mm/s traversing speed, under the exertion of an axial load of 4.87 kN was found to exhibit improved mechanical properties.

Influence of tool rotational speed on microstructural characteristics of dissimilar Mg alloys during friction stir welding

2019 ◽  
Vol 43 (1) ◽  
pp. 132-141 ◽  
Author(s):  
P. Sevvel ◽  
C. Satheesh ◽  
V. Jaiganesh
Keyword(s):  
Friction Stir Welding ◽  
Heat Affected Zone ◽  
Rotational Speed ◽  
Mg Alloy ◽  
Tool Rotational Speed ◽  
Microstructural Characteristics ◽  
Friction Stir ◽  
Dissimilar Friction Stir Welding ◽  
Speed Range ◽  
Az80a Mg Alloy

Dissimilar friction stir welding of the AZ80A Mg alloy as the advancing side and the AZ91C Mg alloy as the retreating side was carried out at a constant feed rate of 75 mm/min using a taper cylindrical pin profiled tool at different tool rotational speeds. Defect free welds were produced in the 700–900 rpm rotational speed range. During friction stir welding, extrusion of metal took place in the advancing side and this extruded material was dynamically recrystallized and redeposited on the retreating side. This experimental investigation revealed that friction stir welding leads to the formation of comparatively finer sized grains on the retreating side of the thermo-mechanically affected zone compared to grains in the thermo-mechanically affected zone on the advancing side. Moreover, the heat affected zone of AZ80A possessed fine sized grains compared to the heat affected zone of AZ91C. Additionally, increasing tool rotational speed influenced the tensile strength of the fabricated joints.

Mathematical Model to Predict Tensile Strength of Underwater Friction Stir Welded (UFSW) on 5052 Aluminium Alloys

2018 ◽  
Author(s):  
Dhanis Paramaguru ◽  
Srinivasa Rao Pedapati ◽  
Mokhtar Awang ◽  
Hamed Mohebbi
Keyword(s):  
Mechanical Properties ◽  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Polynomial Regression ◽  
Coefficient Of Determination ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir

In this study, AA5052 joints are fabricated by underwater friction stir welding and the process parameters are optimized for maximum UTS value by utilizing a developed mathematical model. The experiments are conducted by using Taguchi’s L9 orthogonal array, and polynomial regression analysis is applied to generate the model. Statistical tools such as analysis of variance (ANOVA), coefficient of determination is applied to check the adequacy of the developed model at 95% confidence level. Type of welding tools is identified as the most influencing factor on deciding the mechanical properties of the joint, followed by tool rotational speed and tool welding speed. The optimum process parameters are identified by the Taguchi parametric design method. The results indicated that the optimum process parameters combinations for better mechanical properties is attained at tool rotational speed of 1500 rpm and tool welding speed of 100 mm/min, using taper threaded cylindrical tool. A maximum UTS value of 225.48 MPa is obtained and it is verified by confirmation test.

Mechanical Properties Evaluation of Friction Stir Welded AA6061-AA7075 Alloys for Different Tool pin Geometries

2019 ◽  
Vol 895 ◽  
pp. 295-300
Author(s):  
Rao R. Raghavendra ◽  
N. Bharath ◽  
S. Pradeep ◽  
C.K. Yogisha
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Dissimilar Materials ◽  
Hardness Test ◽  
Green Technology ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Solidification Cracks ◽  
Tool Pin

The friction stir welding is a solid state welding in which welding takes place at a temperature below the melting point. This welding is also known as green technology welding as no harmful gases are generated, as well as fluxes are not formed. In this process joining of two dissimilar materials can be achieved. Through this welding one can overcome defects like porosity, solidification, cracks etc by selecting suitable wilding parameters. Present work investigates the effect of different tool pin geometries on mechanical properties of friction stir welded AA6061 and AA7075 alloys keeping the process parameters constant. The welding is carried with process parameters 1000rpm, 50mm/min and 5KN as tool rotational speed, welding speed and axial load respectively, and for four different pin geometries: (a) cylindrical pin, (B) triangular pin, (c) square pin and (d) hexagonal pin. The welded samples are characterized by mechanical properties like tensile strength and micro Vickers hardness test. By considering the both properties the hexagonal pin shown better characteristics under optimum process parameters.

Sign in / Sign up

Export Citation Format

Share Document