Process optimization in the self-reacting friction stir welding of aluminum 6061-T6

Trueba, Luis; Torres, Monica A.; Johannes, Lucie B.; Rybicki, Daniel J.

doi:10.1007/s12289-017-1365-4

Cited by 39 publications

(22 citation statements)

References 20 publications

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“…This is because, according to investigations, the tool feed rate regulates the heat flux conferred to the joint during the process [53]. According to Luis Trueba Jr et al [54] remarkably, situations that would have led to hot weld conditions (high rotational speed and low traverse speed) is one confirmation. This can be explained further by recalling that one of the purposes of the shoulders is to constrain plasticized weld metal and with increased traverse rates, the ability of the shoulders to constrain weld metal is reduced.…”

Section: Influence Of Traverse Speed Of On Tensile and Hardness Strenmentioning

confidence: 99%

Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Asmare

Al-Sabur

Sefene

2020

Metals

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The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

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Section: Influence Of Traverse Speed Of On Tensile and Hardness Strenmentioning

confidence: 99%

Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Asmare

Al-Sabur

Sefene

2020

Metals

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“…The general area of interest for the BFSW process is welding of light-alloys sheets, where there are many applications for this in marine, automotive, and aerospace fabrication processes [7][8][9]. Since, existence of defects can directly affect weld properties, making a reliable weld by the FSW process, in different situations and with different parameters, is difficult.…”

Section: Introductionmentioning

confidence: 99%

Structural Anatomy of Tunnel Void Defect in Bobbin Friction Stir Welding, Elucidated by the Analogue Modelling

Tamadon

Pons

Clucas

2019

ASI

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The potential position for tunnel defect within the structure of bobbin-tool friction stir welds was studied by analogue modelling. The welding process was simulated on layered plasticine slabs instead, compared to the aluminum plates. Observations in the modelled structure showed a high possibility for a continuous channelled discontinuity, like a tunnel-shaped void defect, in the entry zone of the weld, which mirrors the metal welding. The anatomy of tunnel defect in the entry zone was explained according to the mechanics of material during the plastic deformation process.

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“…Trueba et al [21] performed an optimization experiment using a factorial design to evaluate the effect of process parameters on the weld temperature, surface and internal quality, and mechanical properties during bobbin-tool friction stir welding. To evaluate the surface appearance, a semi-quantitative visual appearance rating (VAR) was developed based on the presence and severity of visually observable defects.…”

Section: State Of the Art-evaluation Of The Surface Of Friction Stir mentioning

confidence: 99%

Improving the surface quality of friction stir welds using reinforcement learning and Bayesian optimization

Hartl

Hansjakob

Zaeh

2020

Int J Adv Manuf Technol

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Friction stir welding is an advanced joining technology that is particularly suitable for aluminum alloys. Various studies have shown a significant dependence of the welding quality on the welding speed and the rotational speed of the tool. Frequently, an inappropriate setting of these parameters can be detected through an examination of the resulting surface defects, such as increased flash formation or surface galling. In this work, two different learning-based algorithms were applied to improve the surface topography of friction stir welds. For this purpose, the surface topographies of 262 welds, which were performed as part of ten studies, were evaluated offline. The aim was to use reinforcement learning and Bayesian optimization approaches to determine the most appropriate settings for the welding speed and the rotational speed of the tool. The optimization problem was solved using reinforcement learning, specifically value iteration. However, the value iteration algorithm was not efficient, since all actions and states had to be iterated over, i.e., each possible parameter combination had to be evaluated, to find the best policy. Instead, it was better to solve the optimization problem directly using the Bayesian optimization. Two approaches were applied: both an approach in which the information from the other studies was not used and an approach in which the information from the other studies was used. On average, both the Bayesian optimization approaches found suitable welding parameters significantly faster than a random search algorithm, and the latter approach improved the result even further compared with the former approach. Future research will aim to show that optimization of the surface topography also leads to an increase in the ultimate tensile strength.

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Process optimization in the self-reacting friction stir welding of aluminum 6061-T6

Cited by 39 publications

References 20 publications

Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

Structural Anatomy of Tunnel Void Defect in Bobbin Friction Stir Welding, Elucidated by the Analogue Modelling

Improving the surface quality of friction stir welds using reinforcement learning and Bayesian optimization

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