Optimization of friction stir welding parameters during joining of AA3103 and AA7075 aluminium alloys using Taguchi method

Raj, Anil; Kumar, J. Pratap; Rego, Anil Melwin; Rout, Ivan Sunit

doi:10.1016/j.matpr.2021.02.246

Cited by 18 publications

(8 citation statements)

References 12 publications

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“…e friction stir welding method uses a tool that rotates with shoulder and pin pro les embedded into the edges or surfaces of two workpieces in a butt joint con guration. e tool travels along the workpiece joint line [1][2][3]. In FSW, the welding tool rotation and tool progress directions determine the advancing and retreating side orientations.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Temperature Distribution and Mechanical Properties of Friction Stir Welding of Al-Cu Joints Using Hardened H13 Steel Tools

Kumar

Raj

Venkatraman³

et al. 2022

Advances in Materials Science and Engineering

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Friction Stir Welding (FSW) is a superior metal joining technique for joining similar and dissimilar metals. The various materials acceptable for the FSW techniques were magnesium alloys, mild steel, stainless steel, copper alloys, titanium alloys, aluminium alloys, etc. In this method, the frictional heat generated by the tool on metal workpieces was used for joining, and the workpieces were joined below the upper critical temperature. The substantial benefit of this technique is that it is capable of welding unweldable alloys by the conventional fusion welding method. The welding tool was rotated, traversed, and penetrated into the joint between two base plates. A suitable tool design with appropriate process parameters will result in high-quality welding on workpieces. In these experiments, the tools were designed with different pin profiles. The welding tools required for FSW are designed using SOLIDWORKS, and temperature distributions across the weld regions were analyzed using Ansys software. The fixture needed for FSW is fabricated according to machine requirements. The tool material used was hardened H13 steel, and the base plates were aluminium alloy 6101 and copper alloy C11000. The temperature distributions are noted in each trial during FSW of Al-Cu joints along the weld line region. Due to maximum temperature at weld joints, high ultimate tensile strength and impact strength were obtained at 1200 rpm tool rotational speed and 20 mm/min feed rate with the square pin profile of a hardened H13 steel tool. The obtained ultimate tensile stress (UTS) at joints was less than that of the base plates Al and Cu. The microhardness value was higher at the nugget zone than at the base plates, giving high strength at the joint area and unevenly distributed.

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Section: Introductionmentioning

confidence: 99%

Analysis of Temperature Distribution and Mechanical Properties of Friction Stir Welding of Al-Cu Joints Using Hardened H13 Steel Tools

Kumar

Raj

Venkatraman³

et al. 2022

Advances in Materials Science and Engineering

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“…To improve this rst trial, Analysis of Variance (ANOVA) was conducted from which resulted the identi cation and elimination of irrelevant factors and levels [18]- [20]. Hence, D was dropped and a reworked DoE with 3 factors at 2 levels was carried out, as can be seen in Table 5.…”

Section: Design Of Experiments (Doe)mentioning

confidence: 99%

Thermally Induced Reduction of Hot Cracking Susceptibility in Electron Beam Welding of CuCr1Zr: A Numerical Approach

Chin

Effertz

Pires

et al. 2021

Preprint

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Electron Beam Welding (EBW) is a highly effective and accurate welding process that is being increasingly used in industrial work and is of growing importance in manufacturing. In the current study, solidification cracking in EBW of a CuCr1Zr cylindrical geometry was explored. To investigate and prevent occurrence of hot cracking, a thermomechanically coupled numerical model was developed using Finite Element Method (FEM). An additional heat source was considered, in order to influence the resulting residual stress state, namely to minimize tensile stresses in the fusion zone during solidification. Hence, a methodical assessment of relevant parameters, such as the power, the diameter of the additional heat source and the distances between both heat sources was employed using Design of Experiments (DoE). It was found that for a particular parameter configuration, solidification cracking most likely could be averted.

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“…FSW helps to join the Al-alloys series (7xxx and 2xxx), which is difficult to weld from traditional welding. The FSW performed at the lowest temperature avoids ease of melting the base plates, less protection, and environmental issues, is fault-free, and reveals finer mechanical characteristics [1][2][3][4][5]. In FSW, while welding, the tool slips over the surface of the plates.…”

Section: Introductionmentioning

confidence: 99%

Experimental analysis and RSM-based optimization of friction stir welding joints made of the alloys AA6101 and C11000

Kumar

Raj

Kulandaivel³

et al. 2023

Mater. Res. Express

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In the present study, the evaluation of FSW input parameters on output response ultimate tensile strength (UTS) of the friction stir welded AA6101-C11000 joint is in agreement. The response surface methodology (RSM) was adapted for generating the mathematical regression equation to predict the UTS and to develop the FSW parameters to attain the highest UTS of the FSW joints. The central composite design (CCD) method from RSM with five levels and three factors, i.e., tool rotational speed, feed rate, and tool offset used to conduct and minimize the number of tests. During FSW, base sheet cu (hard metal) was stationed on the advancing side (+1 mm, +1.68 mm tool offset) and the base sheet Al (soft metal) on the retreating side (-1 mm, -1.68 mm tool offset). The radiography studies were accomplished to inspect the internal flaws of the FSW joints (Al-Cu).The XRD and SEM investigation of the ruptured specimens during the tensile test to evaluate the IMCs phase anatomy and fracture analysis. The maximum UTS value measured during the experimental work was 142.69 MPa at 1000 rpm, 40 mm/min, and -1.68 mm tool offset. The highest joint efficiency obtained was 82% compared with the AA6101 UTS value. RSM adapted for this work was 92% accurate and satisfactory.

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Optimization of friction stir welding parameters during joining of AA3103 and AA7075 aluminium alloys using Taguchi method

Cited by 18 publications

References 12 publications

Analysis of Temperature Distribution and Mechanical Properties of Friction Stir Welding of Al-Cu Joints Using Hardened H13 Steel Tools

Analysis of Temperature Distribution and Mechanical Properties of Friction Stir Welding of Al-Cu Joints Using Hardened H13 Steel Tools

Thermally Induced Reduction of Hot Cracking Susceptibility in Electron Beam Welding of CuCr1Zr: A Numerical Approach

Experimental analysis and RSM-based optimization of friction stir welding joints made of the alloys AA6101 and C11000

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