scholarly journals Process Parameters Optimization for Maximizing Tensile Strength in Friction Stir-Welded Carbon Steel

2021 ◽  
Vol 67 (6) ◽  
pp. 311-321
Author(s):  
Anmol Bhatia ◽  
Reeta Wattal
Keyword(s):  
Tensile Strength ◽  
Carbon Steel ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Welding Speed ◽  
Parameters Optimization ◽  
Percentage Reduction ◽  
Percentage Elongation ◽  
Friction Stir ◽  
Shoulder Diameter

The present study focuses on improving the ultimate tensile strength of friction stir welded carbon steel (AISI 1018). The effect of the process parameters (welding speed, tool RPM, and shoulder diameter) on the response parameters (ultimate tensile strength, percentage elongation and percentage reduction in area) were studied. Response surface methodology was used to develop the mathematical model for response parameters, and the adequacy of the model was checked using analysis of variance (ANOVA). The welding speed and tool RPM were found to affect the ultimate tensile strength significantly. The percentage elongation was affected only by welding speed. The percentage reduction in the area was affected by welding speed and shoulder diameter. The microstructure and microhardness of the weld have been studied and reported in the study.

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.

Multi-response optimization of friction stir welding process parameters for dissimilar joining of Al6101 to pure copper using standard deviation based TOPSIS method

2019 ◽  
Vol 233 (18) ◽  
pp. 6473-6482 ◽  
Author(s):  
Nidhi Sharma ◽  
Zahid A Khan ◽  
Arshad Noor Siddiquee ◽  
Mohd Atif Wahid
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Welding Speed ◽  
Welding Process ◽  
Micro Hardness ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Response Optimization

Friction stir welding is a new and effective solid-state welding process for joining dissimilar materials such as aluminum (Al) and copper (Cu). Joint quality of the friction stir welded materials gets influenced by the welding strategy and different friction stir welding process parameters, i.e. rotational speed, welding speed, tool design, tool pin offset, and tilt angle. In this paper, the effect of combination of different friction stir welding process parameters during joining of Al-6101 and pure copper is studied using Taguchi L18 orthogonal array. Four friction stir welding process parameters, i.e. shoulder diameter (A), pin offset (B), welding speed (C), and rotational speed (D) each at three levels except shoulder diameter, which is at two levels are selected. The effect of different combinations of these parameters on ultimate tensile strength and micro-hardness of the joints is investigated. Subsequently, single response optimization for ultimate tensile strength and micro-hardness and multi-response optimization of ultimate tensile strength and micro-hardness taken together is carried out to obtain the optimal combination of the friction stir welding process parameters. Taguchi method is used for single response optimization, whereas Taguchi-based TOPSIS method is employed for multi-response optimization. For single optimization, the optimum combination of the friction stir welding parameters yielding maximum strength and micro-hardness are A1B1C2D2 and A2B1C2D3, respectively. The optimum combination of the process parameters for multi-response optimization is A2B1C2D2. From the results of the study for single- and multi-response optimization, it is revealed that the rotational speed is the most significant process parameter affecting the tensile strength and micro-hardness of the joints followed by the welding speed. Further, the macro/microstructure and micro-hardness profile of the joint obtained at the optimal combination of the multi-response optimization are given and discussed for better understanding of material mixing and joining.

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.

Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments

2016 ◽  
Vol 232 (8) ◽  
pp. 1384-1394 ◽  
Author(s):  
R Palanivel ◽  
RF Laubscher ◽  
S Vigneshwaran ◽  
I Dinaharan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Ultimate Tensile Strength ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.

Effect of Process Parameters on Defect Formation in Friction Stir Processed 6082-T6 Aluminium Alloy

2012 ◽  
Vol 232 ◽  
pp. 3-7
Author(s):  
Akinlabi Esther Titilayo ◽  
Akinlabi Stephen Akinwale
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Feed Rate ◽  
Rotational Speed ◽  
Defect Formation ◽  
Processing Parameters ◽  
Friction Stir

This paper reports the effects of processing parameters on defects formed during friction stir processing of 6082-T6 Aluminium Alloy. The plates were processed by varying the feed rate between 50 and 250 mm/min, while the rotational speed was varied between 1500 and 3500 rpm to achieve the best result. It was observed that the sheets processed at the highest feed rate considered in this research resulted in wormhole defect. These processed samples with defects were correlated to the tensile results and it was found that the Ultimate Tensile Strength (UTS) of these samples was relatively low compared to other samples without defects.

scholarly journals Combined Response Surface Method and Modified Differential Evolution for Parameter Optimization of Friction Stir Welding

Processes ◽  
2020 ◽  
Vol 8 (9) ◽  
pp. 1080
Author(s):  
Thanatkij Srichok ◽  
Rapeepan Pitakaso ◽  
Kanchana Sethanan ◽  
Worapot Sirirak ◽  
Parama Kwangmuang
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Differential Evolution ◽  
Welding Speed ◽  
Tool Material ◽  
Optimal Parameters ◽  
Friction Stir ◽  
Surface Method ◽  
Tool Pin

In this study, we constructed a new algorithm to determine the optimal parameters for friction stir welding including rotational speed, welding speed, axial force, tool pin profile, and tool material. The objective of welding is to maximize the ultimate tensile strength of the welded aluminum. The proposed method combines the response surface method and the modified differential evolution algorithm (RSM-MDE). RSM-MDE is a method that involves both experimental and simulation procedures. It is composed of four steps: (1) finding the number of parameters and their levels that affect the efficiency of the friction stir welding, (2) using RSM to formulate the regression model, (3) using the MDE algorithm to find the optimal parameter of the regression model obtained from (2), and (4) verifying the results obtained from step (3). The optimal parameters generated by the RSM-MDE method were a rotation speed of 1417.68 rpm, a welding speed of 60.21 mm/min, an axial force of 8.44 kN, a hexagon-tapered tool pin profile, and the SKD 11 tool material. The ultimate tensile strength obtained from this set of parameters was 294.84 MPa, which was better than that of the RSM by 1.48%.

Effect of Welding Speed on Mechanical Properties of Friction Stir Welded AA 6082-T6 Al Alloy

2018 ◽  
Vol 877 ◽  
pp. 98-103
Author(s):  
Dhananjayulu Avula ◽  
D.K. Dwivedi
Keyword(s):  
Tensile Strength ◽  
Welding Speed ◽  
Welded Joint ◽  
Al Alloy ◽  
Microstructural Properties ◽  
Nugget Zone ◽  
Percentage Elongation ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties ◽  
Hardness Values

In this study the effect of process parameters on mechanical and microstructural properties of similar AA6082-T6 joints produced by friction stir welding was investigated. Different samples were produced by varying the transverse welding speeds of the tool from 19 to 75 mm/min and a fixed rotational speed of 635 rpm. A more uniform hardness values in the nugget zone were observed at 48 mm/min welding speed. The lowest hardness values were recorded on nugget zone at all the welding speeds. The increase in welding speed increases ultimate tensile strength and reaches maximum and further increase in welding speed results decrease in tensile strength were observed. The welded joint has highest joint efficiency (52.33 %) obtained at the welding speed of 48 mm/min. Similarly with the increase in welding speed decrease in the percentage elongation were recorded.

Study of the performance parameters of friction stir welded magnesium AZ31B alloy at optimized process parameters

2021 ◽  
pp. 095440622199240
Author(s):  
Pradeep K Yadav ◽  
Manoj K Khurana
Keyword(s):  
Process Parameters ◽  
Grey Relation Analysis ◽  
Percentage Elongation ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Analysis Technique ◽  
Shoulder Diameter ◽  
Optimum Response ◽  
Az31b Alloy ◽  
Grey Relation

The present study is aimed to analyze the effect of process parameters on the qualities of the Friction Stir Welded AZ31B Mg Alloy. Response Surface Methodology based Grey Relation Analysis technique was used to multi-optimization of the response parameters such as tensile strength (TS), percentage elongation (El), microhardness (MH), and impact strength (IMP). The mathematical models for response parameters were developed by considering tool rotational speed (RS), tool shoulder diameter (SD), and welding speed (WS) as process parameters. ANOVA (Analysis of Variance) was performed to check the adequacy of the formulated mathematical model and figure out the significant parameters. The results revealed that RS of 950 rpm, WS of 150 mm/min, and SD of 11 mm are the optimal process parameters for optimum response parameters (TS of 157.8700 MPa, IMP of 4.3001 Joule, MH of 84.1335 Hv, and El of 10.0071%). WS is the most significant factor, followed by RS and SD. The grain growth was observed in thermo-mechanically affected zone (TMAZ). The fracture analysis indicated that crack had initiated from the bottom of the centerline in the welded zone and propagated towards the advancing side.

Estimation and Comparison of Welding Responses Using MRA, GMDH and ANN Technique of Al6061 and Al7075 Material in FSW

2019 ◽  
Author(s):  
Ugrasen Gonchikar ◽  
Holalu Venkatadasu Ravindra ◽  
Prathik Jain Sudhir ◽  
Umeshgowda Bettahally Mahadevegowda ◽  
Shankarnarayan Maskibail Suresh
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Solid State ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Alloying Elements ◽  
Friction Stir ◽  
Al 6061 ◽  
Al 7075

Abstract Friction Stir Welding (FSW) is a solid state welding which uses non-consumable steel rod to weld two materials. Friction stir welding is an emerging process which is based on frictional heat generated through contact between a non-consumable rotating tool and work piece. Friction stir welding technique possesses several advantages over other conventional types of welding due to the fact that process is carried out in solid state. Removal of melting helps in minimizing porosity and eliminates oxide inclusion. In this study, we focus on the optimization of the process parameters in friction stir welding of two different aluminium alloys (6061, 7075) using Taguchi method of experimental design. Al 6061 and Al 7075 are the two different alloys of aluminium. Among these Al 7075 has mechanical properties nearly double than that of Al 6061, but Al 6061 is used more extensively than Al 7075 because of its low cost. Al 6061 and Al 7075 being alloys of aluminium varies in the composition of alloying elements used in their manufacturing. Al 6061 has magnesium and silicon as its major alloying elements whereas Al 7075 has zinc as its primary alloying element. Al 6061 comes with medium to high strength, exhibit good toughness and surface finish, excellent resistance to corrosion at environmental conditions and another important property is its good weldability. Al 7075 being stronger than Al 6061 lacks in its resistance to corrosion and has poor weldability. Al 6061 is readily weldable but Al 7075 is not, because it is prone to micro-cracking during welding. This study also describes the relation between process parameters and their response of friction stir weld on ultimate tensile strength and hardness of composite materials using mathematical models. The process parameters considered are rotational speed, welding speed and number of passes. Different methodologies are used to develop the models to predict the responses and mechanical properties such as ultimate tensile strength and hardness. The objective of Multiple Regression Analysis (MRA) is to construct a model that explains as much as possible, the variability in a dependent variable, using several independent variables. Group Method of data Handling Technique (GMDH) is a family of inductive algorithms for computer-based mathematical modelling of multi-parametric datasets that features fully automatic structural and parametric optimization of models. GMDH is used in such fields as data mining, knowledge discovery, prediction, complex systems modelling, optimization and pattern recognition. As the machining process is non-linear and time dependent, it is difficult for the traditional identification methods to provide an accurate model. Compared to traditional computing methods, the Artificial Neural Network’s (ANN) are robust and global. Estimation and comparison of machining responses were carried out by MRA, GMDH and ANN.

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