Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Sabry, Nicholas; Stroh, Joshua; Sediako, Dimitry

doi:10.1016/j.cirpj.2022.11.021

Cited by 19 publications

(8 citation statements)

References 28 publications

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“…k Lastly, the grey relational coefficient, k , i ( ) x also plays a crucial role. After finding the best process parameters for maximum GRG value, we predict the optimal GRG using equation (17). A confirmation test is then done to validate our prediction.…”

Section: Grg Creationmentioning

confidence: 99%

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Process parameters settings of friction stir welding using multi-response optimization for aluminum alloys

Pandav,

Patil,

Pandipati

2024

Eng. Res. Express

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The defense and aerospace industries utilize the AA2050, an aluminum-lithium alloy of the third generation. Principal component analysis (PCA) and Taguchi-grey relational analysis (GRA) are utilized in this study to enhance the process constraints for friction stir welding (FSW). The quality of the weld can be influenced by various process factors such as the speed at which the weld is traversed, the speed at which the tool is rotated, the angle at which the tool is tilted, the diameter of the shoulder, and the shape of the tool pin. The combination of PCA and the well-known Taguchi-GRA approach enables the objective estimation of response weights. Here, a Taguchi L16 orthogonal array was designed, and sixteen tests were carried out using it. These experiments were conducted with various assessments including tensile strength, yield strength, elongation percentage, hardness of the weld zone, bending load, etc. Through the utilization of Taguchi-GRA-PCA analysis, the most suitable process parameters were identified as a traverse speed (TS) of 160 mm/min, a rotating speed (RS) of 900 rpm, a tilt angle (TA) of 2 degrees, a shoulder diameter (SD) of 16 mm, and with a straight square tool pin profile (TPP). ANOVA revealed the relevance of all five characteristics, with rotational speed being the most influential, accounting for 43.56% of the entire result. A confirmation experiment done under ideal conditions revealed a significant improvement in total weld quality of 19.06%.

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Section: Grg Creationmentioning

confidence: 99%

“…After identifying the optimal parameter levels, the Taguchi-GRA-PCA analysis concludes with predicting and proving GRG improvement, also known as overall weld quality in this study. The projected total weld quality was estimated using equation (17). To validate the analytical results, a confirmation test was performed.…”

Section: Confirmation Testmentioning

confidence: 99%

Process parameters settings of friction stir welding using multi-response optimization for aluminum alloys

Pandav,

Patil,

Pandipati

2024

Eng. Res. Express

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“…To examine the microstructure and identify any welding flaws, the scanning electron microscope was utilized. The fusion of dissimilar aluminum alloys is typically accomplished through the application of FSW [22].…”

Section: Introductionmentioning

confidence: 99%

Material selection for milling fixture of friction stir welding using simulia

Pandav,

Patil,

Pandipati

2024

Eng. Res. Express

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Friction stir welding is an innovative welding technique that joins two different materialswithout the need for consumables. The process involves a profiled probe and shoulder toolthat is rotated and plunged between the two workpieces at the interface during the friction stirprocess. The weld zone undergoes dynamic recrystallization, resulting in a strong bondbetween the materials. This method offers superior bonding compared to traditional arcwelding. In the context of conventional or non-traditional milling machines, friction stirwelding is performed. It is necessary to use a milling fixture to attach the plates that need tobe butt and lap welded, fixture can be used in underwater FSW. To ensure the workpiece issecurely held in place, a fixture or holder is necessary. In this article, friction-stir welding,and a fixture with a clamping setup are constructed. The fixture is carefully designed toconsider the movement of the instrument and workpiece, and it is manufactured usingCatiaV6 3D experience software. The fixture is then subjected to three different types oftesting using Simulia software. The materials tested include cast iron, die steel, and tool steel.After simulation analysis, the best material for friction-stir welding operations is selected.

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“…The change in mechanical properties caused by the mixing of materials in the stirring zone can play a crucial role in determining the formation of residual states in FSW of dissimilar metals. The resulting stresses are highly relevant to the process parameters and tool geometries in FSW of dissimilar metals [42]. Recrystallization plays a key role in this process [43].…”

Section: Introductionmentioning

confidence: 99%

Subregion Based Prediction of Residual States in Friction Stir Welding of Dissimilar Metals

Zhang,

Wang,

Liu

et al. 2023

Coatings

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Mechanical property changes in friction stir welding can directly affect the rebalance of the stress field in friction stir welding. This means that it reveals a high relevance with the residual states of friction stir welding. Here, we propose a subregion model in which the mechanical property changes are considered to predict the residual states in friction stir welding of dissimilar metals. Results indicate that the accuracy of the predicted distortion can be greatly increased when the different mechanical properties are considered in friction stir welding of 2024-T3 and 6061-T6. The final mechanical property is determined by the mixture of the materials at retreating and advancing sides. The final mechanical property in the stirring zone can be increased to 171 MPa for yield strength and 194 MPa for tensile strength when the strength of the advancing side material is higher. The shrinkage of material in the stirring zone during the cooling stage is the key reason for the formation of the tensile residual stress and the V-shape distortion on the cross-section in the as-weld state.

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Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Cited by 19 publications

References 28 publications

Process parameters settings of friction stir welding using multi-response optimization for aluminum alloys

Process parameters settings of friction stir welding using multi-response optimization for aluminum alloys

Material selection for milling fixture of friction stir welding using simulia

Subregion Based Prediction of Residual States in Friction Stir Welding of Dissimilar Metals

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