Influence of Friction Stir Welding Parameters on Dissimilar Joints AA6061-T6 and AA5052-H32

Balamurugan, S.; Jayakumar, K.; Subbaiah, K.

doi:10.1007/s13369-021-05773-7

Cited by 32 publications

(12 citation statements)

References 40 publications

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“…After all measurements, the differences in the overall contribution percentages % between parameters range from 0 to 46 %. The degrees based on AHP between equal importance (1) and absolutely more important (9) are built according to these differences in the overall contributions. According to the measurements, the contribution of 5.75 % is the transition value from a degree to a higher one of importance.…”

Section: Ahp For Fsw Parametersmentioning

confidence: 99%

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

2022

J Mod Ind Manuf

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Objective: This study aims to rank friction stir welding parameters using the analytic hierarchy process (AHP). Methods:The proposed approach includes two phases to achieve a general ranking of the parameters through the separate estimation of their weights on each metal type and aggregation. The criteria used in the AHP for ranking are the contribution percentages and the degrees of the parameters obtained from the analysis of variance of experimental studies. The data were obtained from literature that used the design of experimental arrays to optimize these parameters on multiple properties and many similar and dissimilar metals. Fourteen parameters were assigned in the present analysis, namely rotational speed (RS), traverse speed (TS), axial force (AF), pin profile (PP), tilt angle (TA), the ratio between shoulder diameter and pin diameter (D/d ratio), shoulder diameter (SD), pin diameter (Pd), plunge depth (PD), pin length (PL), tool offset (TO), shoulder concavity (SC), number of passes (NOP) and base metal side (BMS). Results:The parameters were classified into highly significant, moderately significant, and insignificant based on their rankings. The RS, TS, TA, and PP were the highest-ranking parameters with a total contribution of 83.4% to outputs. The insignificant parameters included the D/d ratio, BMS, SC, AF, and Pd, with a low total contribution of 14%. The moderately significant parameters were the TO, NOP, SD, PD, and PL. Conclusion:The above-mentioned significant parameters could be controlled to maximize the response. The failure to achieve the target specified in the standard by controlling only highly significant parameters signifies a need for further modification of the FSW process. Therefore, parameters of moderate significance are potential parameters that need to be controlled to achieve the target. To limit the selection between these parameters, reference should be made to the type of metal used and then the parameters with the greatest impact on the metal are selected, i.e. controlling PL for aluminum, NOP, and SD for magnesium, and TO for aluminum-to-steel and aluminum-to-copper.

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Section: Ahp For Fsw Parametersmentioning

confidence: 99%

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

2022

J Mod Ind Manuf

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“…The optimization of pin profile in addition to rotational and traverse speeds has been also investigated [30][31][32][33][34]. Sefene et al [30] studied multi-responses of hardness and tensile on AA6061 similar joints with a thickness of 5 mm using gray relation with Taguchi L9OA (3P:3L (1/3 of 3 3 )).…”

Section: Introductionmentioning

confidence: 99%

“…Meengam and Sillapasa [32] used a full factorial design of L64OA (3P:4L) for the optimization of AA6063 (6 mm) FSW joints. Balamurugan et al [33] studied the tensile response of dissimilar joints of AA5052-H32/AA6061-T6 with a thickness of 5 mm using Taguchi L27OA (3P:3L). Raj et al [34] used L9OA to optimize the parameters of AA3013/AA7075 dissimilar joints.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of process parameters for friction stir welding of dissimilar aluminum alloys using different Taguchi arrays

Elnabi

Mokadem

Osman

2022

Int J Adv Manuf Technol

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A statistical optimization based on experimental work was conducted to consider ultimate tensile strength (UTS) and elongation of dissimilar joints between AA5454 and AA7075 by friction stir weld (FSW). The goal of this work is to develop a comparative study of the optimization of FSW parameters using different orthogonal arrays, i.e., L12 and L16. Four parameters correlated to softening and forging requirements (rotational speed, traverse speed, tilt angle, and plunge depth), one parameter associated with the location of base metal in the dissimilar joint, and two parameters related to an FSW tool (pin profile and Dshoulder/dpin ratio) were considered and arranged in the employed arrays. Moreover, the investigation explored the microstructure and fractography of dissimilar joints and base metals by using optical and scanning electron microscopes. The results showed that the L16OA is more accurate than L12OA for the optimization of seven parameters due to the small statistical errors. For UTS, the errors range from 0.78 to 24% for L16OA and from 27.23 to 44.14% for L12OA. For elongation, the errors run from 11 to 12.9% for L16OA and from 33.77 to 49.73% for L12OA. The accuracies of generated models range from 50 to 99.5% for L16OA and range from 30.7 to 94.9% for L12OA. Tightening the levels (narrow domain) is the main reason for switching some optimum levels between both arrays. The highest UTS obtained is 221 MPa based on the optimum levels attained from L16OA, and the highest elongation is 12.83% according to the optimum levels acquired from L12OA. Despite the deficiency of effective intermixing, the study revealed that FSW acceptably could assemble joints between AA5454 and AA7075, presenting the proficiency of FSW with welding dissimilar aluminum alloys.

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“…(Balamurugan et al 2021 and Biplab Ghosh et al 2022). The sides of the SS tool cause the base materials to flow in batches when the tool traverses the joining face, whereas threaded and tapered tool profiles do not cause pulsating action because of the absence of flat surfaces.…”

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confidence: 99%

Influence of tool pin profiles in the strength enhancement of friction stir welded AA5083 and AA5754 alloys

Kumar¹,

Jayakumar²

2022

Mater. Res. Express

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Friction stir welding (FSW) is a well-known technology for joining similar and dissimilar materials. The quality of the weld in FSW is affected by the various process parameters such as tool rotational speed (TRS), tool transverse speed (TTS) and tool pin profiles. This study aims to investigate the effect of three different tool pin profiles on the variation of microstructure and mechanical strength of friction stir welded AA5083 and AA5754 alloys joints. Both of these alloys combinations offer excellent corrosion resistance and formability. As a result, they're commonly seen in tanks, pressure vessels, shipyards, and trucks. In this work, the FSW methodology focused on varying the TRS of 750, 1000, 1250 and 1500 rpm and TTS as 20, 30, 40 and 50 mm/min. The surface microstructures of the weldments were analyzed using an optical microscope and scanning electron microscope. Tensile and Microhardness tests were carried out on the weldments to determine the weld strength. Three variety of tool pins, namely straight square, threaded cylinder, and straight cylinder were used for this study. The microstructural and the mechanical properties analysis of the welded samples proved that the straight square tool pin profile is suitable for joining AA5083 and AA5754 alloys. The weldments prepared using a straight square pin profile exhibited good material stream behaviour, uniform spreading of plastic deformation in the weld zone and aided in the reduction of formation of macroscopic defects on the welded zone. Among the process parameters, it was detected that the pin profile displays more impact on tensile strength followed by tool rotation speed and welding speed. According to the findings, the dissimilar weld joint formed at the optimum process parameters had the highest tensile strength of 212 MPa and hardness of 88 HV were: Square Tool Profile, 1250 rpm TRS, and 40 mm/min TTS.

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Influence of Friction Stir Welding Parameters on Dissimilar Joints AA6061-T6 and AA5052-H32

Cited by 32 publications

References 40 publications

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

Optimization of process parameters for friction stir welding of dissimilar aluminum alloys using different Taguchi arrays

Influence of tool pin profiles in the strength enhancement of friction stir welded AA5083 and AA5754 alloys

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