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.
Today, tailored welded blank sheets have found various applications in automotive, aeronautic and many other industrial fields. One of the most efficient methods for production of tailored welded blank sheets is application of the friction stir welding process. In the present article, the effect of friction stir welding parameters on the microstructure and mechanical properties of heterogeneous tailored welded blank sheets made from aluminium alloys of types 5083-H12 and 6061-T6 with the similar thickness of 1.5 mm is studied. The considered parameters are rotational speed of the tool, linear speed of the tool, pin diameter and shoulder diameter. In order to come by a tailored welded blank sheet with optimal mechanical properties, response surface methodology, which is considered as a strong tool in design of experiments, has been employed to design the experiment matrix, and the corresponding experiments have been conducted under laboratory conditions. Tensile strength of tailored welded blank sheets are determined as the relation in the mathematical model. The optimal condition and objective effects of parameters are determined via this relation. Data variance analysis showed that rotational speed and diameter tool have the most and the least effect on tensile strength, respectively. Rotational and linear speed are more effective than pin and shoulder diameter in input heat, which is produced by friction.
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.
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