A Soft Computing-Based Analysis of Cutting Rate and Recast Layer Thickness for AZ31 Alloy on WEDM Using RSM-MOPSO

In the present research, the AZ31 alloy is machined by wire-cut electric discharge machining (WEDM). The experiments were designed according to the Box-Behnken design (BBD) of response surface methodology (RSM). The input process variables, namely servo feed (SF), pulse on-time (Ton), servo voltage (SV), and pulse off-time (Toff), were planned by BBD, and experiments were performed to investigate the cutting rate (CR) and recast layer thickness (RCL). The analysis of variance (ANOVA) was performed to determine the influence of machining variables on response characteristics. The empirical models developed for CR and RCL were solved using Multi-Objective Particle Swarm Optimization (MOPSO). Pareto optimal front is used for the collective optimization of CR and RCL. The optimal solution suggested by the hybrid approach of RSM-MOPSO is further verified using a confirmation test on the random setting indicated by the hybrid algorithm. It is found that the minimum RCL (6.34 µm) is obtained at SF: 1700; SV: 51 V; Toff: 10.5 µs; and Ton: 0.5 µs. However, maximum CR (3.18 m/min) is predicted at SF: 1900; SV: 40 V; Toff: 7 µs; and Ton: 0.9 µs. The error percentage of ±5.3% between the experimental results and predicted solutions confirms the suitability of the proposed hybrid approach for WEDM of AZ31.

Effects of Residual Stresses on the Fatigue Lifetimes of Self-Piercing Riveted Joints of AZ31 Mg Alloy and Al5052 Al Alloy Sheets

During the self-piercing riveting (SPR) process, residual stress develops due to the high plastic deformation of the sheet materials. In this study, the effect of the residual stress on the fatigue lifetime of SPR joints with dissimilar magnesium AZ31 alloy and aluminum Al5052 alloy sheets was evaluated. The residual stress distribution was derived through a simulation of the SPR process by the FEA (finite element analysis). The measured values by the X-ray diffraction technique confirmed that the validity of the simulation has a maximum error of 17.2% with the experimental results. The fatigue strength of the SPR joint was evaluated at various loading angles using tensile-shear and cross-shaped specimens. It was found that the compressive residual stresses of the joint reduce the stress amplitude by 13% at 106 cycles lifetime, resulting in extension of its lifetime to approximately 3.4 million cycles from 106 cycles lifetime. Finally, it was confirmed that the fatigue life of SPR joints was appropriately predicted within a factor of three using the relationship between the fatigue life and the equivalent stress intensity factor. The fatigue resistance of the magnesium AZ31 alloy on the upper sheet was found to govern fatigue lifetimes of SPR joints of dissimilar magnesium AZ31 alloy sheets.

The Influence of the Mechanism of Double-Sided FSW on Microstructure and Mechanical Performance of AZ31 Alloy

In the friction stir welding (FSW) process, the final performance of weld joints is determined by microstructures influenced mainly by the heat input and mechanical deformation. In this research, the effects of FSW parameters, rotation speeds, and welding passes, on microstructure and mechanical properties of AZ31 alloy were systematically and comparatively studied. It was found that the microstructure at the joint center with multi-pass FSW could obtain a smaller average grain size compared with the single pass. The differences of the grain size were reduced significantly when the samples experienced the double-side FSW process. The mechanical performance results showed that the optimum strength (315 MPa) was achieved through the double-side FSW process with a rotation speed of 500 r/min and welding speed of 60 mm/min. The mechanism of the parameters and double-sided process on mechanical properties of the joint samples was elaborated.

Characterization of the AZ31/AW-6060 Joint Fabricated using Compound Casting with a Zn Interlayer at Relatively Low Temperature Conditions

The work deals with the fabrication of a joint between AZ31 magnesium alloy and AW-6060 aluminium alloy with the use of a Zn interlayer. The Zn layer was produced on the surface of an AW-6060 alloy insert by diffusion bonding. The insert was then placed inside a steel mould and kept at room temperature. The joint was produced using compound casting by filling the mould with liquid AZ31 alloy, heated to 650 °C. The microstructure of the bonding zone formed between joined alloys was analysed using an optical microscope and a scanning electron microscope equipped with an energy dispersive X-ray spectroscope. The properties of the joint were examined using Vickers microhardness measurements and simple shear strength testing. As a result of the experiment, the 400 μm thick bonding zone with a complex microstructure was formed between the alloys. The microstructural analysis showed that the bonding zone reveals a high concentration of Zn and Mg. The layers of a eutectoid (a MgZn phase + a solid solution of Al and Zn in Mg), a Mg5Al2Zn2 phase and a Mg(Al,Zn)2 phase with fine particles of other phases were observed there. The bonding zone was characterized by relatively high microhardness, which was related to the brittleness of the constituents. The shear strength of the examined joint was 19.6 ± 2.5 MPa.