In the present study, friction stir welding (FSW) and tungsten inert gas (TIG) techniques were used to join the dissimilar aluminum alloys of 5083-H12 and 6061-T6. The laboratory tests were designed using design of experiment (DOE) method. Variables for the FSW process were the rotational speed, traverse speed, shoulder diameter, and pin diameter. They changed in ranges of 700-2500 r/min, 25-400 mm/min, 10-14 mm, and 2-4 mm, respectively. In the case of TIG process, the variables were current intensity, traverse speed, and tilt angle. These parameters varied from 80 to 90 A, 200 to 400 mm/min, and 3 to 12 , respectively. The optimum amounts of parameters were obtained using response surface methodology (RSM). The RSM-based model was developed to predict ultimate tensile strength (UTS) of the welds produced. In FSW, the difference between predicted and measured UTS was about 1.28% and in TIG it was 1.78%. The good agreement between experimental and predicted results indicates the high accuracy of the developed model. Mechanical properties and also the microstructure of the welds were compared after optimizing both welding processes using RSM. The results showed that the welds produced by FSW indicated a considerably higher quality and also improved mechanical properties compared to TIG. Properties of the joints obtained by FSW in single-sided joints were more desirable. In the double-sided welds obtained by FSW these differences were of an even higher significance.
Improving quality in today's complicated industrial systems is gaining more and more importance every day. Since applying these systems costs a lot, companies should try to offer the best outcomes and processes possible. One of the products most applied is Tailor Welding Blanks, which is widely used in automobile, aerospace, and other industries. One of the best methods of producing Tailor Welding Blanks is Friction Stir Welding. Using this technology, sheets dissimilar in material and thickness can be joined. In this paper, the possibility of welding thin sheets of 5083-H12 and 6061-T6 aluminum alloy by Friction Stir Welding with the thickness of 1.5 mm is examined. To detect the impact of Friction Stir Welding parameters, i.e. rotational speed (r/min), linear speed (mm/ min), shoulder diameter (mm), and tilt angle (), a Box-Behnken design was used and using multiple Response Surface Methodology values of robust optimization of tensile strength and elongation were derived. The optimization and experiment results were then compared. The results of the comparison showed a good correspondence.
The problems faced are aluminium (Al) waste from industries that damage the environment and scarcity of Al raw materials that need to be recycled from used Al. The research objective was to determine the effect of adding magnesium (Mg) to used Al casting on the tensile strength and microstructure and to determine the comparison of the tensile strength of the Al material used by the piston to the brake lining and drum of motorcycles. The research method includes casting Al used pistons, brake lining and drum, testing the tensile strength and microstructure due to the addition of 0.1; 0.2; 0.5 and 1.0% by weight Mg to the tensile strength and microstructure. The results showed that the addition of Mg 0.5% by weight could increase the tensile strength of 92.96% from 71 MPa to 137 MPa for brake lining as the optimum value which further decreased the tensile strength by 19.7% at the addition of 1% Mg to 110 MPa. Drum material also experienced an increase in tensile strength of 33.71% from 89 MPa to 119 MPa as the optimum value where the tensile strength decreased by 5.88% for the addition of 1% Mg to 112 MPa. The two values of the tensile strength of the brake lining and drum components are lower than those of the piston component valued at 147 MPa, and with the addition of Mg, Mg2Si is formed which can reduce the porosity of the microstructure, thereby increasing its strength.
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