To achieve a defect-free butt joint of dissimilar metals by friction stir welding procedure, there are some major parameters, such as tool material and geometry, tool rotational speed, feed rate and tilt angel. This research is focused on dissimilar metals welding, namely 1100 Al alloy and 1045 carbon steel. In this paper, the effect of tool rotation speed and feed rate are experimentally investigated on surface appearance, microstructure and micro hardness of the friction stir welded plates. Optimum values of tool rotation speed and feed rate have been achieved experimentally by the quality of the butt joint.
ABSTRACT. Performance of Friction Stir Welding (FSW) as a solid-state process is approved in several engineering applications, especially aluminum industries. Identification of mechanical behavior of the associated welded zone is necessary due to these extensive applications of FSW. In this study, considering the effect of rotational and forward speed of welding tool on the mechanical properties of welded region, a hybrid optimization method based on combination of Genetic Algorithm (GA) and Response Surface Method (RSM) named here as GA-RSM is proposed to achieve maximum tensile and ultimate strength. The results of GA-RSM are validated by per-forming necessary experimental tests on two wide-used 2024 and 5050 aluminum alloys. The results show that GA-RSM could be an effective approach to achieve optimized process for FSW with minimum cost.
In this research, effect of tool material and tool offset on tool erosion and metallurgical and mechanical properties of dissimilar friction stir welding of Al alloy to carbon steel are investigated. As the tool erosion is one of the important parameters on the defect-free friction stir welding, especially in butt joint of Al alloy to steel. In present work, different tool material and offset are used in friction stir welding at Al alloy to carbon steel with a constant tool speed and feed rate named as 710 rpm and 28 mm/min respectively. The result of experimental observation is shown better performance by tungsten carbide (WC) tool material with 1 mm offset on Al alloy area.
Difficulty of welding with high strength and resistance to fatigue failure of the aluminum alloys, hindering the widespread use of conventional welding methods for forming such a connection in aerospace applications. These factors led to the junction fusion welding of aluminum alloys methods quite unnoticed. Therefore, the use of solid state welding Friction welding especially Friction Stir Welding (FSW) for joining aluminum alloys system has been used widely. The parameters that effect on process are gender and tool geometry, rotational speed and forward, tilt angle and vertical force noted. In present research, the effect of rotational speed and forward on mechanical properties of 2024 aluminum alloy, evaluated by experiments .in order to do this study, because of the Wide range of parameter variations on mechanical properties, we should do several expensive experimental tests. In order to decrease the amount of experimental tests, Mamdani-Type Fuzzy implication, have been chosen. In this paper, by knowing the capability of fuzzy logic in create an intelligent relationship between the input and output data, the relationship between the forward and rotational speed as an inputs and mechanical properties as an outputs based on experimental data have been proposed. The results indicated that by adopting an appropriate fuzzy method, both the number of experimental tests and mechanical properties of welded FSW, optimized.
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