Aluminum alloys are used in the modern automotive industry because they are lightweight. However, it is establised that conventional fusion welding processes affect weld performance. In this study, friction stir welding (FSW), also known as solid-state welding, was used to weld dissimilar aluminum alloys, AA6061-T6 and AA5083plates. Response surface methodology based on Box-Behnken design (BBD) was used to investigate the appropriate process parameters. In this study, the effects of rotation speed (S), welding feed rate (f), and work angle (θ) were investigated. These three factors were examined at three levels over 17 experimental runs. The design was used to conduct experiments and develop mathematical regression models. Variance analysis was performed to examine the adequacy of the developed models. Finally, the effects of the process parameters on the mechanical properties of welded alloyes were investigated using mathematical models based on the macrostructure, microstructure, chemical composition, and fracture characteristics of the joints using SEM. The investigation found that the optimum welding parameters are a rotational speed of 777 rpm, welding speed of 44 mm/min, and a work angle of 0.75o. Furthermore, the results confirm that the mathematical models and experiments are consistent.
High-strength steel and aluminum alloys are used to manufacture modern vehicles. The objective was to reduce the weight and fuel consumption of the vehicles. In this study the optimum parameters for the friction stir spot welding (FSSW) process between Al6061-T6 aluminum alloy and HSS590 high-strength steel were determined. Response surface methodology based on central composite design (CCD) with three parameters, five levels, and 19 runs was used to conduct experiments and develop mathematical regression models. The three joint parameters were tool speed, welding feed, and dwell time. Analysis of variance was then performed to examine the adequacy of the developed models. Finally, the effects of the process parameters on the mechanical properties were investigated using mathematical models. In addition, the distribution of the chemical composition and fracture characteristics of the joints was examined using scanning electron microscopy (SEM). The investigation found that the optimum welding parameters were a tool speed of 1576 rpm, welding feed rate of 45 mm∙min-1, and dwell time of 10 s. Furthermore, the results confirmed that the mathematical models and experiments were consistent.
This paper aimed to identify the optimal conditions for welding hardfacing by applying the Response Surface Methodology (RSM). The welding heat input, electrode type, and hardfacing layer on wear resistance of welding hardfacing were all optimized using the Box-Behnken experimental design. The findings revealed that these three variables had an impact on the volume loss of welding hardfacing. Because of the high coefficient of determination, the experimental data obtained were to a quadratic equation (96.90%). The ideal condition was determined using a 3D response surface plot and a contour map produced from mathematical models. The following were the ideal welding conditions: With a welding heat input of 1.58 J, a filler metal type of DFA2-600-B, and a third layer of hardfacing, the lower volume loss of the weld was 1.29 mm3.
This study investigates the residual stress and surface roughness of AA5052 aluminum alloy with two points incremental forming (TPIF) processed. The experimental tool used for forming was a ball-shape tool for the truncated cone geometry of workpieces and forming by CNC machines. The residual stress was measured using the experimental forming tool. The residual stress was measured using the X-ray diffraction method. This study aimed to optimize the parameters using the Taguchi and analysis of variance (ANOVA) techniques. The TPIF process parameters include tool rotation speed and incremental depth. The results revealed that the optimal parameter obtained for the lowest residual stress and surface roughness were A1B1 (Rotation speed 0 rpm and Incremental depth 0.3 mm) with residual stress of 21.14 MPa and 0.46 μm of surface roughness. According to the results obtained by ANOVA, it was found that the rotation speed was significant to residual stress and incremental depth insignificant to residual stress. On the other hand, the most significant factor for surface roughness was incremental depth, but rotation speed was insignificant to surface roughness of formed parts at 95% confidence level.
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