Optimization and Mechanical Characterization of AA5083 and AA7075 Dissimilar Aluminium Alloy Joints Produced by Friction Stir Welding

2021 ◽  
Vol 13 (3) ◽  
Author(s):  
S. Rajeshkannan ◽  
M. Vigneshkumar ◽  
V. Gopal ◽  
S. Ramesh
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Axial Force ◽  
Welding Speed ◽  
Rotational Speed ◽  
Frictional Heat ◽  
Friction Stir ◽  
Welding Method ◽  
The Impact

In this research work the aluminium alloys including AA7075 and AA5083 are combined with friction stir welding method. This contrasts with factors such as alloy segregation, hot cracking and porosity which result from fusion welding process in the welded area. In order to generate high quality joint of aluminium alloy, friction-stir welding (FSW) an assuring welding method is followed. To achieve the determined strength, an entire control over the relevant process is needed to increase the tensile vitality. The welding factors like welding speed (WS), axial force (AF) and rotational speed (RS) are examined for optimisation. In order to measure the impact of the factors on tensile strength of FS welded joints, Taguchi L9 orthogonal array technique is employed. The amount of involvement of these factors on weld quality is determined by means of analysis of variance (ANOVA). The utmost ultimate tensile strength (UTS) attained for AA7075 and AA5083 joint is 256MPa. ANOVA results show that the quality-wise effectiveness of the weld as welding speed (5.48percent), axial force (15.18percent), then the rotational speed (79.32percent). This is due to the presence of fine equiaxed grains in the microstructures of the stir zones at different FS welding circumstances. However, a decrease in the grain size of the process zone is observed when the frictional heat flow is decreased while friction-stir welding.

Process Parameters Optimization of Friction Stir Welding in Aluminium Alloy 6063-T6 by Taguchi Method

2017 ◽  
Vol 867 ◽  
pp. 97-104 ◽  
Author(s):  
T. Ganapathy ◽  
K. Lenin ◽  
K. Pannerselvam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Taguchi Method ◽  
Axial Force ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Process Parameter ◽  
Main Process ◽  
Friction Stir

This paper deals with the effective application of friction stir welding similar to butt joining technique.AL6063 T-6 alloys prepared in 125x 100 x 7mm thickness plate and FSW tool setup were H13 of diameter 25mm rotary tool with straight cylindrical pin profile. The maximum strength was considered for selection of combined process parameter. The process parameters were optimized using Taguchi method. The Rotational speed, welding speed, and axial speed are the main process parameter which taken into our consideration. The optimum process parameters are determined with reference to tensile strength of the joint. From the experiments, it was found the effects of welding parameter are the axial force is highest substantial parameter to determining the tensile strength of the joint. The paper which revealed the optimal values of process parameter are to acquire a maximum tensile strength of friction stir welded AL6063-T6 plates is 101.6Mpa with the combination level of rotational speed, welding speed and axial force are found to be 1100 RPM, 60 mm/min and 12.5 KN. validation test was carried out and results were nearer to the optimized results confirmed by the optimum results.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
Anganan K ◽  
Narendran RJ ◽  
Naveen Prabhu N ◽  
Rahul Varma R ◽  
Sivasubramaniyam R
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

scholarly journals Modeling and Optimization of Bobbin Friction Stir Welding for AA6061-T6 alloy Utilizing Response Surface Methodology

2018 ◽  
Vol 26 (4) ◽  
pp. 1-17
Author(s):  
Samir Ali Amin ◽  
Mohannad Yousif Hanna ◽  
Alhamza Farooq Mohamed
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Bending Force ◽  
Speed Range

Bobbin friction stir welding (BFSW) is special kind of friction stir welding. This investigation aims to develop empirical models through mathematical relationships between the welding process parameters and mechanical properties of Aluminum alloy AA6061-T6 welded joint created by using bobbin tool and to find the optimum welding parameters. The welding speed range (40-200 mm/min) and rotational speed range (340-930 rpm) were utilized (as the used input factors) to find their effects on elongation, tensile strength and maximum bending force as the main responses.  These models were built using Design of Experiment (DOE) software ‘version 10’ with Response Surface Methodology (RSM) technique. The models adequacy were tested via the (ANOVA) analysis. The obtained models appeared that as the welding speed or rotational speed increases, the elongation, tensile strength and maximum bending force of the welded joint firstly rise to a maximum value and then drop. The optimum welding parameters were rotational speed (623.949 rpm) and welding speed (128.795 mm/min) with (6.33%), (204 MPa) and (6.216 KN) of elongation, tensile strength and maximum bending force, respectively. A proper harmonization was obtained between the models predicted results and the optimized ones with actual trial with 95% level of confidence.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
K. Anganan ◽  
R.J . Narendran ◽  
N Naveen Prabhu ◽  
R Rahul Varma ◽  
R Sivasubramaniyam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

Friction Stir Welding of Dissimilar AA7075-T6 to AZ31B-H24 Alloys

MRS Advances ◽  
2017 ◽  
Vol 2 (64) ◽  
pp. 4055-4063 ◽  
Author(s):  
D. Hernández-García ◽  
R. Saldaña-Garcés ◽  
F. García-Vázquez ◽  
E.J. Gutiérrez-Castañeda ◽  
R. Deaquino-Lara ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Joint Line ◽  
Friction Stir ◽  
Tool Offset ◽  
Tool Tilt Angle

AbstractIn the present investigation, AA7075-T6 alloys and AZ31B-H24 were joined by the FSW process using the following range of parameters: rotational speed between 200 and 800 rpm, welding speed from 30 to 60 mm/min and a tilt angle from 1° to 3°. In some cases, a tool offset of 1 mm was used into Mg-based alloy. The experimental results show that sound and good joints can be obtained by positioning the tool in the middle of the joint-line using a rotational speed of 200 rpm, a welding speed of 30 mm/min and a tool tilt angle of 1°. The hardness and ultimate tensile strength in the stir zone were 122 Hv and 61.35 MPa, respectively. Also, it is important to mention that the Al3Mg2 and Al12Mg17 intermetallics compounds were observed in the this zone besides some defects like cavities and tunnel.

Effect of Friction Stir Welding Process Parameters on Temperature Profile and Tensile Strength of Dissimilar Aluminum Alloys

2015 ◽  
Vol 813-814 ◽  
pp. 425-430
Author(s):  
Saurabh Kumar Gupta ◽  
K.N. Pandey ◽  
Rajneesh Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Temperature Profile ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Peak Temperature ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

The aim of this research is to study the effect of Friction Stir Welding (FSW) process parameters such as tool rotational speed and welding speed on temperature distribution and tensile strength of dissimilar AA5083-O and AA6063-T6 joint welded by FSW. Peak temperature at retreating side was observed lower as compared to advancing side for each experiment. Peak temperature decreases with decreasing the tool rotational speed but vice versa with welding speed. ANOVA indicated that the temperature profile was strongly dependent on the tool rotation speed than the welding speed and it also showed that welding speed is the main process parameter that has highest effect on tensile strength of welded joint.

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.

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 Investigations on force generation and joint properties of dissimilar thickness friction stir corner welded AA 5086 alloy

2020 ◽  
Vol 40 (1) ◽  
pp. 67-74
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Process ◽  
Spindle Motor ◽  
Parent Material ◽  
Force Generation ◽  
Friction Stir ◽  
Current Consumption ◽  
Spindle Motor Current

The force generation, joint mechanical and metallurgical properties of friction stir corner welded non-heat treatable AA 5086 aluminum alloy are investigated in this paper. The friction stir welding process is carried out with the plate thicknesses of 6 mm and 4 mm. The welding speed, tool rotational speed and tool plunge depth were considered as the process parameters to conduct the welding experiments. The machine spindle motor current consumption and tool down force generation during friction stir welding were analyzed. The microstructures of various joint regions were observed. The tensile samples revealed the tensile strength of 197 MPa with tool rotational and welding speeds of 1,000 rev/min and 150 mm/min respectively, which is 78 % of parent material tensile strength. A maximum micro hardness of 98 HV was observed at thermomechanically joint affected zone, which was welded with tool rotation of 1,000 rev/min and welding speed of 190 mm/min.

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