Production by FSW of free-shape hollow box profile in AA5754 for automotive application

Taavitsainen, Topi; Vilaça, Pedro; Mutanen, Tommi

doi:10.1007/s40194-016-0382-0

Cited by 10 publications

(3 citation statements)

References 23 publications

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“…The range of chosen parameters was identified following a bibliographic consultation, identifying the technological window within to search the optimal set of parameters considering also the effect of the different cooling fluids. 42–49 Two cooling fluids were used: continuous water jet at room temperature and room temperature air. With regard to the output, tensile tests were executed on the FSWed specimens according to UNI EN ISO 6892-1:2020, using a load cell of 50 kN.…”

Section: Artificial Neural Network Modelingmentioning

confidence: 99%

Multiresponse optimization of friction stir welding by an integrated ANN-PSO approach

Quarto

Bocchi

D’Urso

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The optimization of the process performance by considering each process parameter independently is the simplest approach, but its industrial applications are restricted owing to its very limited validity. To overcome this problem, many techniques such as multi-objective optimization techniques, Artificial Neural Network (ANN), and regression analysis have recently received great attention. In this paper, a multiresponse methodology for predicting the main properties and suggesting the optimal process parameters for Friction Stir Welded joints is presented. The dataset applied in the analysis was collected through experimental FSW tests performed on a CNC machine considering different aluminum alloys, process parameters, and cooling fluids. The integrated methodology involves an Artificial Neural Network and a heuristic algorithm, the Particle Swarm Optimization (PSO) and allows to set both input and output values leaving to the PSO algorithm the identification of the other values able to minimize or maximize a predefined objective function, in this case the maximization of both the UTS and the hardness values of the joints. This means that the ANN is interrogated iteratively until the optimum is reached. For this reason, the proposed methodology can be defined as a double direction method. In particular, the double-direction method refers to the possibility of identifying the optimal values of the process parameters (inputs) starting from the desired specifications (outputs) considering that, in the production reality, processes can be constrained by several factors. The results show a good reliability of the approach, since it has been demonstrated that it is able to generate prevision with an error of less than 5%.

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Section: Artificial Neural Network Modelingmentioning

confidence: 99%

Multiresponse optimization of friction stir welding by an integrated ANN-PSO approach

Quarto

Bocchi

D’Urso

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Making free-form hollow box profiles out of the generally thin AA5754 material used in automotive applications is a promising new field in the automobile industry. Crashworthiness and overall performance are greatly improved in FSW parts compared to equivalent PTIG-welded structures [4]. Diffusion becomes more efficient under increasing stress.…”

Section: Introductionmentioning

confidence: 99%

Characterization of pulsed-tungsten inert gas (PTIG) welding on AA5754-H111 alloy: mechanical properties and microstructural analysis

Tamil Kumaran,

Jayakumar,

Amala Mithin Minther Singh

2023

Mater. Res. Express

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Aluminium and its alloys were widely used in engineering because they are lightweight, strong, and resistant to corrosion. However, using standard arc welding techniques can be difficult when dealing with such materials. Pulsed-Tungsten Inert Gas (PTIG) welding is being researched as a potential solution to this problem. This study is the first to investigate the use of the straightforward and intuitive PTIG technique on the ubiquitous AA5754 wrought aluminium alloy. Welded samples were supplied for examination of mechanical parameters such as surface hardness and strength under impact and tensile loading. The results of a statistical analysis of the mechanical characterization of a PTIG-welded permanent joint fabricated from AA5754 aluminium alloy were presented and discussed. The heat-affected zone (HAZ) on the AA5754 retracting side of the weld had a hardness of 50–70 Hv0.5, while the HAZ on the AA5756 side had a hardness of 90–100 Hv0.5, as measured by testing on the perfect weld specimen. Samples taken from different parts of the weldment all showed that the HAZ is the softest and weakest. The shattered surface of the welded sample consisted of flat facets and quasi-cleavage patterns, as revealed by scanning electron microscopy. Analysis of the HAZ microstructure revealed widespread dissolution of Mg2Si precipitates in the AA5754-H111.

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“…FSW is nowadays widely used across many market sectors in the fabrication of safety critical structures, mostly applied to lightweight metals and their alloys [9]. FSW of aluminum [10,11], copper [12,13], and magnesium [14] has had excellent results once the operational parameters have been optimized. This success increased the interest in transferring the benefits of the process to other engineering materials, such as modern steels.…”

Section: Introductionmentioning

confidence: 99%

Effect of processing temperatures on the properties of a high-strength steel welded by FSW

et al. 2018

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The need for weight reduction without compromising load-bearing capacity has driven the development of modern high-strength steels (HSS). The ability to take full advantage of these modern HSS is limited by their weldability. Friction stir welding (FSW) can join HSS at low peak temperatures, better preserving the properties of the base material. This work evaluates the influence of different FSW peak temperatures and cooling rates on the properties of a modern HSS. A HSS produced by a thermomechanically controlled process was welded by FSW with peak temperatures, measured within the processed zone, ranging from about 900 to 650°C. Temperatures were measured using thermocouples positioned at the mid-thickness of the workpiece, at 5 to 10 mm from the joint line. The effect of the different peak temperatures was evaluated by mechanical testing, including bending, tensile testing with digital imaging correlation, Charpy impact test, and hardness measurements. Microscopic analyses, including optical microscopy and electron backscatter diffraction, were used to evaluate the microstructure. Results show that FSW enables welding HSS within the intercritical temperature domain. The impact toughness of the best weld condition overmatched the base material by over 37%, at both − 40 and − 60°C. The yield strength efficiency was about 70%.

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Production by FSW of free-shape hollow box profile in AA5754 for automotive application

Cited by 10 publications

References 23 publications

Multiresponse optimization of friction stir welding by an integrated ANN-PSO approach

Multiresponse optimization of friction stir welding by an integrated ANN-PSO approach

Characterization of pulsed-tungsten inert gas (PTIG) welding on AA5754-H111 alloy: mechanical properties and microstructural analysis

Effect of processing temperatures on the properties of a high-strength steel welded by FSW

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