Optimization of Process Parameters for Improved Corrosion Resistance and Microstructural Exploration in Friction Stir Welding of AA2024 - AA6061

2019 ◽  
Vol 969 ◽  
pp. 589-594
Author(s):  
R. Dinesh Kumar ◽  
D. Srija ◽  
P. Suresh ◽  
S. Muthukumaran
Keyword(s):  
Corrosion Resistance ◽  
Friction Stir Welding ◽  
Optimal Parameter ◽  
Microstructural Analysis ◽  
Traverse Speed ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Three Stages ◽  
Fsw Parameters

The aluminium alloys AA2024 and AA6061 are widely used for fabricating light weight structural member with better strength and corrosion resistance. Friction stir welding (FSW) parameters such as rotational speed, tool shoulder profile and traverse speed are used to identify the corrosion resistance and microstructural analysis in different weld region of AA2024-AA6061 dissimilar joints. In this work, Taguchi L9 orthogonal array with three variables and three stages has been used to reduce the number of experiments. Potentiodynamic polarization (PDP) testing results are optimized by ANOVA technique and obtain the corrosion rate as 5.72 mil/yr and resistance polarization as 835.28 ohm.cm2. The optimal parameter set is found to be 1000 rpm, flat shoulder and 45 mm/min. The microstructural analysis reveals localized pit dissolution in the nugget zoneThe aluminium alloys AA2024 and AA6061 are widely used for fabricating light weight structural member with better strength and corrosion resistance. Friction stir welding (FSW) parameters such as rotational speed, tool shoulder profile and traverse speed are used to identify the corrosion resistance and microstructural analysis in different weld region of AA2024-AA6061 dissimilar joints. In this work, Taguchi L9 orthogonal array with three variables and three stages has been used to reduce the number of experiments. Potentiodynamic polarization (PDP) testing results are optimized by ANOVA technique and obtain the corrosion rate as 5.72 mil/yr and resistance polarization as 835.28 ohm.cm2. The optimal parameter set is found to be 1000 rpm, flat shoulder and 45 mm/min. The microstructural analysis reveals localized pit dissolution in the nugget zone.

scholarly journals Experimental and thermal investigation with optimization on friction stir welding of nylon 6A using Taguchi and microstructural analysis

2021 ◽  
Vol 13 (10) ◽  
pp. 168781402110507
Author(s):  
Gajula Sri Venkata Seshu Kumar ◽  
Anshuman Kumar ◽  
S Rajesh ◽  
Rama Bhadri Raju Chekuri ◽  
Venkatesa Prabhu Sundaramurthy
Keyword(s):  
Friction Stir Welding ◽  
Feed Rate ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Composite Plates ◽  
Friction Stir ◽  
Thermal Investigation ◽  
Operating Process ◽  
Environmentally Friendly Process ◽  
Fsw Parameters

Friction stir welding is an environmentally friendly process of joining due to the non-usage of flux, or any shield gas. Therefore, this article proposes an experimental and thermal investigation with optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS), and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500, 1000, and 1500 rpm as TRS, 30, 40, and 50 mm as feed rate by varying the pitch values as 1, 2, and 3 mm. Further, the analysis of variance (ANOVA) also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively. The experimental and optimum FSW parameters for maximum UTS are obtained at a feed rate of 30 mm/min, tool pitch of 3 mm, and the TRS of 500 rpm.

Evaluation of dissimilar joints properties of 5083-H12 and 6061-T6 aluminum alloys produced by tungsten inert gas and friction stir welding

2015 ◽  
Vol 231 (3) ◽  
pp. 297-308 ◽  
Author(s):  
Morteza Ghaffarpour ◽  
Mohammad Kazemi ◽  
Mohammad Javad Mohammadi Sefat ◽  
Ahmad Aziz ◽  
Kamran Dehghani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Traverse Speed ◽  
Inert Gas ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
The Difference ◽  
Welding Processes

In the present study, friction stir welding (FSW) and tungsten inert gas (TIG) techniques were used to join the dissimilar aluminum alloys of 5083-H12 and 6061-T6. The laboratory tests were designed using design of experiment (DOE) method. Variables for the FSW process were the rotational speed, traverse speed, shoulder diameter, and pin diameter. They changed in ranges of 700–2500 r/min, 25–400 mm/min, 10–14 mm, and 2–4 mm, respectively. In the case of TIG process, the variables were current intensity, traverse speed, and tilt angle. These parameters varied from 80 to 90 A, 200 to 400 mm/min, and 3° to 12°, respectively. The optimum amounts of parameters were obtained using response surface methodology (RSM). The RSM-based model was developed to predict ultimate tensile strength (UTS) of the welds produced. In FSW, the difference between predicted and measured UTS was about 1.28% and in TIG it was 1.78%. The good agreement between experimental and predicted results indicates the high accuracy of the developed model. Mechanical properties and also the microstructure of the welds were compared after optimizing both welding processes using RSM. The results showed that the welds produced by FSW indicated a considerably higher quality and also improved mechanical properties compared to TIG. Properties of the joints obtained by FSW in single-sided joints were more desirable. In the double-sided welds obtained by FSW these differences were of an even higher significance.

The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets

2021 ◽  
Vol 36 (1) ◽  
pp. 94-102
Author(s):  
M. M. Z. Ahmed ◽  
A. Elnaml ◽  
M. Shazly ◽  
M. M. El-Sayed Seleman
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Transverse Cross Section ◽  
Joint Zone ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Fsw Parameters ◽  
Spherulitic Structure

Abstract In this work, top surface lubrication during friction stir welding of polycarbonate sheets was applied. A homogenous layer of Paraffin wax has been placed on the top surface of the joint area with a width that ensures to cover the shoulder diameter. Then FSW was applied using conventional FSW tool with rotating pin and shoulder at different FSW parameters (Rotation speeds of 1 000, 1500, 2 000 min–1 and welding speeds of 25, 50, 75,100 mm/min). The main objective of using the wax is to act as a lubricant that reduces the friction between the shoulder and the polycarbonate surface. The joints produced were investigated in terms of surface quality, internal defects, and mechanical properties. During FSW the wax is melted and played as lubricant between the tool shoulder and the polycarbonate surface and resulted in defect-free surface with no thickness reduction of the original plate. The transverse cross-section showed defect-free joints for the majority of the FSW parameters investigated. Tensile testing results showed a reduction of the tensile strength after FSW, and an enhancement in the tensile strength with the increase of welding speed or rotation speed. The fracture occurs at the joint zone and the fracture surface investigation using SEM showed the existence of spherulitic structure in the weld joint.

scholarly journals Parametric optimization of friction stir welding of Al-Mg-Si alloy: A case study

2021 ◽  
pp. 7-7
Author(s):  
Nasir Khan ◽  
Sandeep Rathee ◽  
Manu Srivastav
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Automobile Construction ◽  
Input Variables

Al-Mg-Si alloys have wide applications in industries such as aerospace, marine, automobile, construction. In this work, newly developed friction stir welding (FSW) was utilized for joining of AA6082-T6 alloy. The effect of major FSW process variables like rotational speed, traverse speed, and shoulder diameter of tool is studied over microstructural and mechanical characteristics of friction stir welded (FSWed) joints. Experimental design was done using Taguchi method (L9 orthogonal array). Three factors viz. rotational speed, welding speed, and diameter of tool shoulder were taken at three levels each. Mathematical modelling was developed in order to optimize the tensile strength of weld joints. Analysis of variance (ANOVA) was utilized to determine the percentage contribution of input variables. The results of present study exhibits that shoulder diameter, rotation, and welding speed of tool significantly affect the mechanical strength of FSWed joints.

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

2019 ◽  
Vol 234 (5) ◽  
pp. 1031-1043
Author(s):  
Arshad Noor Siddiquee ◽  
Sunil Pandey ◽  
Mustufa Haider Abidi ◽  
Abdulrahman Al-Ahmari ◽  
Noor Zaman Khan ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Traverse Speed ◽  
304 Stainless Steel ◽  
Welding Parameters ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter

Welding AISI 304 stainless steel is challenging, especially as fusion-based welding processes (such as arc welding) severely undermine the material's corrosion resistance due to sensitization. Solid-state friction stir welding is one of the most suitable alternatives. Friction stir welding of high-strength high-softening materials such as AISI 304 is difficult mainly because of the non-availability of affordable tools and tool life. In this study, AISI 304 stainless steel was successfully butt-welded by friction stir welding. The experiments were performed using Taguchi's L27 orthogonal array. Shoulder diameter, tool r/min, and traverse speed were selected as the most influential welding parameters. A Tungsten Carbide (WC) tool was employed with a tapered pin profile. Defect-free joints were fabricated successfully for all the welding conditions. Microstructural examinations using optical microscopy and scanning electron microscopy revealed significant grain refinement in the stir zone and the presence of distinct structural features such as stepped, dual, and ditch in various characteristics zones. The presence of precipitates was also observed in samples and was confirmed via energy-dispersive X-ray spectroscopy analysis. The in-process traverse force was measured by a special arrangement of force measuring units attached to the work fixture. The traverse force data were analyzed and optimized. The results of an analysis of variance reveal that the traverse speed was the most important parameter, followed by tool r/min, interaction between the tool shoulder diameter and traverse speed, interaction between the tool shoulder diameter and tool r/min, and, finally, the tool r/min.

scholarly journals The effect of material position of multi-pass friction stir processing on friction stir welded AA1050/AA6082 dissimilar joints

2021 ◽  
Vol 309 ◽  
pp. 01001
Author(s):  
Oritonda Muribwathoho ◽  
Velaphi Msomi ◽  
Ali Merdji ◽  
Sipokazi Mabuwa
Keyword(s):  
Grain Size ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Friction Stir Processing ◽  
Vickers Microhardness ◽  
Microstructural Analysis ◽  
Dissimilar Joint ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Number Of Passes

The AA1050 and AA6082 plates were used in producing dissimilar joint through friction stir welding (FSW) technique. The developed dissimilar joint was then subjected to multi-pass friction stir processing (FSP) technique. Various tests for the AA1050/AA6082 (AA1050 on the advancing side) and AA6082/AA1050 (AA6082 on the advancing side) joints were conducted on joints subjected to 1pass (1P) and 4pass (4P). The microstructural analysis showed that the increase in number of FSP passes resulted in a reduced grain size regardless of the of material position. The Vickers microhardness for AA1050/AA6082 FSPed joints increased towards AA6082 side while the microhardness for AA6082/AA1050 FSPed joints decreased towards the AA 1050 side regardless the number of the passes. The ultimate tensile strength (UTS) of AA1050/AA6082 joint increased with an increase in the number of passes while AA6082/AA1050 fluctuated between the specimens sampled from different locations of the FSPed joints.

The Impact of Material Positioning Towards the Friction Stir Welded Dissimilar Aluminium Alloy Joints

2020 ◽  
Vol 13 ◽  
Author(s):  
Velaphi Msomi ◽  
Sipokazi Mabuwa
Keyword(s):  
Microstructural Analysis ◽  
Ductile Failure ◽  
Dissimilar Materials ◽  
Traverse Speed ◽  
Tensile Tests ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Strength Alloy ◽  
Materials Used ◽  
The Impact

Background: Friction stir welding is at an advanced state such that it could be used to joint dissimilar materials and alloys. However, there are some areas which require some further analysis. This involves the impact of the material positioning of various dissimilar joints. Objective: The purpose of this paper is to investigate the influence of material positioning towards the microstructure and the mechanical properties of AA8011/AA6082 and AA6082/AA8011 dissimilar joints. Methods: The materials used in this study were the 6mm thick AA8011 and AA6082-T6 plates. The welding conditions include a tool rotational speed of 1100 rpm, traverse speed of 60 mm/min. Microstructural analysis, Vickers hardness and tensile tests were conducted in order to be able to draw a comparison between the respective joints. Results: The joints (AA8011/AA6082 and AA6082/AA8011) both experienced dynamic recrystallization. The positioning of the stronger strength alloy on the advancing side resulted in finer microstructural grains compared to when the lower strength alloy was positioned on the advancing side. The maximum stir zone hardness of 75 HV was obtained on the AA8011/AA6082 dissimilar joint, while the AA6082/AA8011 had a minimum hardness of 68 HV. Both hardness values were lower than the AA6082 hardness but greater than that of the AA8011. The positioning of AA6082 on the advancing side resulted in higher ultimate tensile strength than when AA8011 was on the advancing side. The AA6082/AA8011 joint was found to be more ductile in comparison to the AA8011/AA6082 joint. The fracture surface morphology of the post tensile specimens also revealed a ductile failure morphology. Conclusion: Placing the stronger strength alloy on the advancing side resulted in sound overall results of the tests conducted.

scholarly journals Experimental Investigation and Optimization on Friction Stir Welding of Nylon 6A Using Taguchi and ANOVA with Microstructural Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
G. S. V. Seshu Kumar ◽  
Anshuman Kumar ◽  
S. Rajesh ◽  
Rama Bhadri Raju Chekuri ◽  
Amsalu Gosu Adigo
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Feed Rate ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Composite Plates ◽  
Friction Stir ◽  
Operating Process ◽  
Environmentally Friendly Process ◽  
Fsw Parameters

Friction stir welding is an environmentally friendly process of joining due to the nonusage of flux, or any shield gas, and it does not produce any harmful gases when compared to the joining process of fusion. Therefore, this article proposes an experimental investigation and optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS) and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500 rpm, 1000 rpm, and 1500 rpm as TRS, and 30 mm, 40 mm, and 50 mm as feed rate by varying the pitch values as 1 mm, 2 mm, and 3 mm. Further, the analysis of variance (ANOVA) is also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively.

Parametric optimization of friction stir welding process for marine grade aluminum alloy

2019 ◽  
Vol 10 (2) ◽  
pp. 162-175 ◽  
Author(s):  
Amit Goyal ◽  
Ramesh Kumar Garg
Keyword(s):  
Friction Stir Welding ◽  
Yield Strength ◽  
Welding Process ◽  
Tool Material ◽  
Weld Nugget ◽  
Quadratic Model ◽  
Content Type ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Fsw Parameters

Purpose The purpose of this paper is to deal with the experimental data related to the friction stir welding (FSW) of marine grade Al-Mg4.2 alloy. Mathematical models are developed to study the individual and interaction effects of input variables on the performance characteristics of joints. FSW parameters are optimized to maximize the yield strength and weld nugget microhardness of the welded joints. Design/methodology/approach Response surface methodology is applied to establish the mathematical relationship between six input factors, namely, tool rotational speed, transverse speed, tool shoulder diameter, tool material hardness, tilt angle and pin profile; and two response variables, namely, yield strength and weld nugget microhardness. Six factors–five-level rotatable central composite matrix is used for the design of experiments. The quadratic model is used, as suggested by the design expert software, to express the response parameters as a function of investigated input parameters. The competence of the developed models is verified through analysis of variance. Findings The present investigation clearly indicates that the studied input factors have a significant effect on the quality of the joints. The optimal combination of input factors is determined to achieve the desired responses. Originality/value This paper teems a new look on tensile and hardness properties of Al-Mg4.2 joints by relating the microstructure, fractrographs and grains distribution with the dynamic recrystallization and plasticized material movement during the FSW process. The outcome of this research will help in seizing the opportunities of joining Al-Mg4.2 alloy using FSW, in the offshore and marine applications.

scholarly journals Effects of the FSW Parameters on Microstructure and Electrical Properties in Al 6061-T6- Cu C11000 Plate Joints

Crystals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 21
Author(s):  
Daniel García-Navarro ◽  
Juan Carlos Ortiz-Cuellar ◽  
Jesús Salvador Galindo-Valdés ◽  
Josué Gómez-Casas ◽  
Carlos Rodrigo Muñiz-Valdez ◽  
...  
Keyword(s):  
Electrical Resistivity ◽  
Friction Stir Welding ◽  
Electrical Properties ◽  
Weld Zone ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Traverse Speed ◽  
Friction Stir ◽  
Fsw Parameters ◽  
Pure Cu

Friction Stir Welding (FSW) is a feasible welding process to join dissimilar materials due to its solid-state nature. In this study the FSW of 6061-T6 aluminum with pure Cu plates was performed with the objective of evaluating the effects of the FSW parameters on the microstructure and electrical properties. The processing parameters (rotational and traverse speeds) were established to reduce the common defects in the friction-stir welding process. Therefore, the obtained results validated the better mechanical properties and a smaller increase of the electrical resistivity. The rotational speeds used were of 1000, 1150, and 1300 rpm, and the traverse speeds of 20, 40, and 60 mm/min, with the purpose of varying the heat input of the process. The microstructural characterization revealed the presence of a mixture of aluminum and copper into the weld zone, along with copper particles and the formation of intermetallic compounds. It was found that the electrical resistivity of the joints ranged from 0.029 to 0.036 μΩ. The highest electrical resistivity values were obtained at the lowest traverse speed (20 mm/min) and the lowest resistivity values were obtained at highest traverse speed (60 mm/min).

Sign in / Sign up

Export Citation Format

Share Document