Process Parameters Optimization for Friction Stir Welding of Pure Aluminium to Brass (CuZn30) using Taguchi Technique

Elfar, O. M. R.; Rashad, R. M.; Megahed, Hassan

doi:10.1051/matecconf/20164303005

Cited by 12 publications

(9 citation statements)

References 6 publications

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“…Tool design and machine parameters influence the stirring quality in the weld zone [5]. Recently, FSW has been used to join various metal combinations, e.g., dissimilar aluminum alloys [6,7], aluminum to brass/copper [8,9], aluminum to steel [10,11], aluminum to magnesium [12], and aluminum to titanium [13].…”

Section: Introductionmentioning

confidence: 99%

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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Section: Introductionmentioning

confidence: 99%

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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“…At (lowest TRS and highest DT) combination of welding parameters, the highest joint strength was observed. Elfar et al (2016) investigated the effect of FSSW parameters i.e. rotational speed, transverse speed and pin off set on tensile strength for aluminium and brass using L9 OA.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of shear force and fractography of friction stir spot welded joints of AA 6082-T6 alloy

Kumar¹,

Jambhale²,

Maurya³

et al. 2021

JER is an international, peer-reviewed journal that publishes f

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This experimental work investigates the tensile behavior of friction stir spot welded joints from 3 mm thick aluminum alloy AA6082-T6 sheets. Taguchi L9 Orthogonal array was used for process parameters - Tool rotational speed (TRS), Dwell time (DT) and Shoulder diameter (SD) with consideration of three levels. Friction Stir Spot Welding (FSSW) was performed on vertical milling machine. Tensile shear test was conducted on Universal testing machine (UTM) to find out the tensile shear failure load (TSFL). The optimal combinations of parameters were at tool rotational speed of 2,000 rpm, dwell time of 15 seconds and tool shoulder diameter of 16 mm. Tool rotational speed had a substantial effect on tensile shear strength of FSSW joint. Scanning Electron Microscopy (SEM) tests revealed that the changes in microstructure in different zones of FSSW joint were observed. Tensile shear specimen was analyzed using SEM to observe the behavior of fracture surfaces. Significant ductility in the fracture surface was an evident in the fractography. In this article, attention is focused on the influence of joining parameters on the mechanical behavior of the friction stir spot weld under the tensile shear load condition. Keywords: Fractography; friction stir spot welding (FSSW); heat affected zone (HAZ); scanning electron microscopy (SEM); thermo-mechanically affected zone (TMAZ).

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“…This process was primarily used for joining aluminium and aluminium alloys (Thomas and Nicholas, 1997). Over the past decade, researchers have also successfully welded dissimilar metals such as aluminium alloys (Devaiah, Kishore and Laxminarayana, 2018;Elnabi et al, 2018;Muthu Krishnan et al, 2018;Abd Elnabi et al, 2019;Eskandari et al, 2019), aluminium alloys and copper (Zhang et al, 2014;Aliha et al, 2019;Muhammad and Wu, 2019;Rzaev et al, 2019;Shankar et al, 2019), aluminium and brass (Esmaeili et al, 2011b(Esmaeili et al, , 2011b(Esmaeili et al, , 2012Shojaeefard et al, 2013;Elfar et al, 2016), aluminium and magnesium (Jayaraj et al, 2017;Paradiso et al, 2017;Abdollahzadeh et al, 2019;Md and Birru, 2019), aluminium and nickel (Zheng et al, 2017), aluminium and steel (Kasai et al, 2015;Pourali et al, 2017;Hatano et al, 2018;Helal et al, 2019) and aluminium and titanium (Wu et al, 2015;Choi et al, 2018;Yu et al, 2019). The FSW process produces a weld with minimum defects as compared to fusion welding.…”

Section: Introductionmentioning

confidence: 99%

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

Panaskar

Terkar

2020

WJE

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Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

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Process Parameters Optimization for Friction Stir Welding of Pure Aluminium to Brass (CuZn30) using Taguchi Technique

Cited by 12 publications

References 6 publications

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

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

Evaluation of shear force and fractography of friction stir spot welded joints of AA 6082-T6 alloy

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

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