Optimization of process parameters of friction stir welding for Al-Cu joints using Taguchi method. JSS MAHAVIDHYAPEETHA JSS ACADEMY OF TECHNICAL EDUCATION, NOIDA DEPARTMENT OF MECHANICAL ENGINEERING (original) (raw)
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Effect of FSW Process Parameters on Properties of Aluminium Joints
Biuletyn Instytutu Spawalnictwa, 2017
Ever since its development in the 1990s, the friction stir welding method (FSW) has been increasingly popular in various industrial sectors, e.g. in transport, power engineering or electronic industry. In spite of its numerous advantages in comparison with conventional joining methods, the FSW method continues to be intensively investigates to develop appropriate technological parameters and geometry of tools ensuring the obtainment of joints characterised by excellent properties. The process of optimisation is required for each new material. The adjustment of proper FSW process parameters, particularly the tool rate of rotation and the travel rate, enables the obtainment of imperfection-free joints as well as significantly affects process efficiency decreasing its laboriousness and costs. The article addresses issues connected with the optimisation of the FSW process by analysing the effects of changes in the tool travel rate and the rate of rotation on structural and mechanical properties of aluminium joints. The tests involved the use of aluminium alloy grade 6063. The test joints were subjected to visual tests, hardness tests, microstructural examination, static tensile tests etc.
Investigations into FSW joints of dissimilar aluminum alloys
Materials Today: Proceedings, 2019
Joining technique Friction stir welding (FSW) widely accepted for developing new joints of like and unlike metals for wide applications. In present experimental study, two dissimilar aluminium alloys, AA 5086 and AA6061 of 6 mm thickness are welded together using FSW. Nine experiments carried out on a vertical milling machine using a suitable fixture with strong holding aluminium plates on it. Experiments are executed by varying process parameters, which includes speed of tool rotation, welding speed and offset of tool at three levels each. Experiments are performed as per design of experiment using Taguchi's L9 orthogonal array. Mechanical properties tensile strength is tested and compared with base metal properties. Optimum levels are determined with the help of a statistical optimization tool, ANOVA.
Evaluation of FSW Process Parameters of Dissimilar Aluminium Alloys
Innovative Systems Design and Engineering, 2016
Friction stir welding (FSW) is relatively a new welding technology applied to join weldable Aluminum alloys and non- weldable Aluminum alloys that are widely used in many industrial applications such as aerospace, marine, automotive, and other industrial applications. In present research, dissimilar AA2024-T3 and AA6061-T6 Aluminum alloys of 3mm thickness was butt joined by using friction stir welding. The experimental study to optimize the welding parameters on tensile strength and bending test was carried out by Taguchi’s L9 orthogonal array. Experiments have been employed based on four welding parameters, namely, the tool traverse speed, rotational speed, tilt angle of tool and tool geometry. ANOVA technique and signal to Noise ratio were used to determine the most significant parameter that affects the mechanical properties of the weldment. X-ray radiographic, microstructure, microhardness tests have been conducted to demonstrate that samples subjected to the optimum welding par...
Friction stir welding (FSW) process is a promising solid-state joining process with the potential to join low-melting point material, particularly, aluminium alloy. The most attractive reason for joining aluminium alloy with this process is the avoidance of the solidification defects formed by conventional fusion welding processes. In this research article, an attempt has been made to develop an empirical relationship between FSW variables and Micro Hardness. A factorial design was used by considering three factor and eight trials, which enables to quantify the direct and interactive effect of three numeric factors, that is, tool rotational speed, welding speed, and shoulder diameter on the Micro Hardness. The developed relationship is useful for prediction of Micro Hardness in friction stir welded AA6061 aluminium alloy joints at 95% confidence level. It will also be helpful for selection of process variable to obtain the desired strength of the joint. Furthermore, the optimized capabilities in design-expert software were used to numerically optimize the input parameters. I. INTRODUCTION In many industrial applications steel is readily replaced by non-ferrous alloy, in most cases aluminium alloys. Some of these materials combine mechanical strength comparable with structural steel and low weight, allowing for a significant reduction of weight. But the joining of aluminium alloys can sometimes cause a serious problem by the conventional welding process. The difficulty is often attributed to the solidification process and structure including loss of alloying elements and presence of segregation and porosities. Friction stir welding (FSW) offers an alternative through solid-state bonding, which eliminates all these problems of solidification associated with the conventional fusion welding processes. The dependence on friction and plastic work for the heat source precludes significant melting in the work piece, avoiding many of the difficulties arising from a change in states, such as changes in gas solubility and volumetric changes, which often plague fusion welding processes. Further, the reduced welding temperature makes possible dramatically lower distortion and residual stresses, enabling improved fatigue performance and new construction techniques and making possible the welding of very thin and thick materials. FSW has also been shown to eliminate or dramatically reduce the formation of hazardous fumes and reduces energy consumption during welding, reducing the environmental impact of the joining process. Further, FSW can be used in any orientation without regard to the influence of gravitational effects on the process. These distinctions from conventional arc welding processes make FSW a valuable manufacturing process with undeniable technical, economic, and environmental benefits. The process and the terminology are schematically explained in Fig: 1.1. The welding process parameters such as tool rotational speed, welding speed, and pin diameter play a major role in deciding the weld quality. In general, the solid-state nature of the FSW process, combined with its unusual tool and asymmetric nature, results in a highly characteristic microstructure. The microstructure can be broken up into the following zones as explained in Fig: 1.2.
FSW Welding of Aluminium Casting Alloys
Archives of Foundry Engineering, 2016
The article contains basic information associated with the impact of the FSW process parameters on the forming of a weld while friction welding of aluminium casting alloys. Research was conducted using specially made samples containing a rod of casting alloy mounted in the wrought alloy in the selected area of FSW tool acting. Research has thrown light on the process of joining materials of significantly dissimilar physical properties, such as casting alloys and wrought alloys. Metallographic testing of a weld area has revealed the big impact of welding conditions, especially tool rotational speed, on the degree of metal stirring, grain refinement and shape factor of a weld. As the result of research it has been stated that at the high tool rotational speed, the metals stirring in a weld is significantly greater than in case of welding at low rotational speeds, however this fails to influence the strength of a weld. Plastic strain occurring while welding causes very high refinement ...
The present study investigates the effect of joining parameters on the mechanical characteristics of dissimilar friction stir spot welding (FSSW) between aluminum alloys and galvanized steel. Mechanical performance has been evaluated by shear and microhardness testing. A macrostructural examination has revealed the creation of mechanical interlocking in the Al steel connections. Shear failure load has increased with increasing both tool rotational speed and plunge depth for all FSSW connections. Higher plunge depth has improved the mechanical interlocking between lower and upper sheet due to the formation of hook.
2013
Aluminium alloys have gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to weight ratio and good corrosion resistance. Modern structural concepts demand reductions in both the weight as well as the cost of the production and fabrication of materials. Compared to the fusion welding processes that are routinely used for joining structural aluminium alloys, friction stir welding (FSW) process is an emerging solid state joining process was invented in 1991 by TWI, in which the material that is being welded does not melt and recast. The major advantage in FSW process is that the maximum temperature reached is less than 80% of the melting temperature (TM), i.e. the joint is performed in the solid-state and excessive micro structural degradation of the weld zone is avoided. This process uses a nonconsumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial forc...
FSW of AA-2014, Optimization of welding conditions for improved weld joint efficiency
Friction Stir Welding is a novel solid state joining technique employed mostly for joining of Al-alloys. The current study focuses on the optimization of welding parameters for FSwelding of AA-2014. The aim of the study is to determine the best set of FSW parameters, tool design, temper conditions of base metal and PWHT in order to obtain maximum weld strength as compared to unwelded AA-2014 strength in T-6 condition. As a result, the Optimum set of weld parameters like tool rotation, travel speed and tilt angle are determined. Better joint efficiency (joint strength as compared to base metal strength in T-6 condition) is obtained for S.T. condition as compared to T-6 temper
Experimental, Mechanical Characterizations of Friction Welding of Steel and Aluminium Joints
Journal of Advances in Manufacturing Engineering, 2020
Rotary friction welding (RFW) is a solid-state joining process which works by rotating one workpiece relative to another while under a compressive axial force, which produces coalescence of materials workpieces. It is considered most viable alternative to overcome the difficulties faced in conventional joining techniques. As it is a solid state welding process, the process does not form molten pool thereby eliminating the solidification errors. It offers many advantages for some manufacturing sectors for a wide range of applications. In this research, we investigated the mechanical and metallurgical characteristics of RFW welded joints for homogenous and heterogeneous assemblies. We have studied A60 steels and 2017A series aluminum alloys. The obtained welds are similar in appearance in that they have several Microstructural distinct zones. So, the results show that by increasing the rotating speed employing 1000 and 1600 rpm, the mechanical properties during the RFW process is lightly improved, favored by the increase in heat flow. In the same specimen, the micro hardness distribution is generally viewed lightly changed between center line throw weld of welded tube and close to their boundary line. This is due to the no-uniform of temperature distribution in cross section. Thus, plastic deformation of heated portion of the metal plays an important role in friction welding process and their quality. Microstructural analysis reveals that grain growth in the joint WCZ and in heat affected zone HAZ because of the no-uniform of thermal flux distribution in both directions (transvers and longitudinal of tube). Finally using RFW, the fabricators allow to perform and maintenance the mechanical components with low cost and which it conserves their welding quality compared to the classical fusion welding.