Comparison of Mechanical Characteristics of Conventional and Underwater Friction Stir Welding of AA 6063 Pipe Joints

2021

JMES

Self Cite

Demand for metal matrix composites (MMCs) is expected to increase in these applications, such as ‎in the aerospace and automotive sectors. Adequate joining techniques, which are important for ‎structural materials, have not yet been developed for Metal Matrix Composite (MMCs), however. ‎This work aimed to demonstrate the feasibility of ‎friction stir welding (FSW) and ‎underwater friction stir welding (UFSW) for joining Al 6061/5, Al 6061/10, and Al ‎‎6061/18 wt. %SiC composites have been produced by utilizing reinforce stir casting technique. Two ‎rotational ‎speeds,1000and 1800 rpm, and traverse speed 10mm \ min were examined. Specimen ‎composite plates 10 mm thick have been successfully welded by FSW. For FSW and UFSW, a tool ‎made of high-speed steel (HSS) with a conical pin shape was used. The result revealed that the ‎ultimate tensile strength of the welded joint by FSW and UFSW at rotation speed 1800 rpm for (Al ‎‎6061/18 wt. ‎‎% SiC composites) was 195 MPa and 230 MPa respectively. The ultimate ‎tensile ‎strength of the welded joint by FSW and UFSW (Al 6061/18 wt.% SiCe composites) was 165 MPa ‎and 180 MPa at rotation speed ‎‎1000 rpm respectively. The microstructural assessment showed that due ‎to larger grain sizes at FSW and UFSW, most of the fractures are located in the thermal ‎mechanically affected zone (TMAZ) adjacent to the weld nugget zone (WNZ). It is observed that in ‎failure, most of the joints show ductile features. As the volume fraction of SiC (18 wt.%) increases, ‎the friction stir welded and underwater friction stir welded efficiency decreases.

Section: Introductionmentioning

confidence: 95%

Section: Mechanical Characterizationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Investigation of microstructure and mechanical characteristic of underwater friction stir welding for Aluminum 6061 alloy – Silicon carbide (SiC) metal matrix composite

2021

JMES

Self Cite

“…However, as compared to FSW, UWFSW is less prone to these flaws [6]. Sabry et al [7] documented that multiobjective optimization of the UWFSW process was a desirable feature because UWFSW had a high UTS of 218 MPa and a nugget zone hardness of 83 VHN compared to 201 MPa and 65 VHN for the traditional process. Researchers have successfully welded and studied plates and pipes constructed of aluminum alloys such as Al AA 6063-T6 [8], Al 6063 [9], Al 6061 [10], Al 1050 [11], and Al 1050 [12].…”

Section: Introductionmentioning

confidence: 99%

Underwater friction-stir welding of a stir-cast AA6061-SiC metal matrix composite: optimization of the process parameters, microstructural characterization, and mechanical properties

Materials Science-Poland

Hewidy

2022

Self Cite

It is an underlying fact for the case of the joining process especially welding to have optimized parameters to achieve joints with outstanding mechanical characteristics. In the current article, using stir-cast aluminum-based alloy (Al 6061) is stir-cast with Al 6061/5%wt. silicon carbide, Al 6061/10%wt. silicon carbide, and Al 6061/18%wt. silicon carbide was welded using an underwater friction-stir welding process. Optimum welding parameters [namely, tool rotating speed (N), welding speed (S), and silicon carbide (SiC)] are investigated using analysis of variance (ANOVA) and response surface methodology (RSM) statistical approaches. High ultimate tensile strength and microhardness were set as required characteristics of quality welds. Since there are two responses and two objectives, multiple-criteria decision-making approach—response surface methodology was performed alongside ANOVA. Optimal parameters from these statistical approaches are converged to a tool rotating speed of 1,736.36 rpm, a welding speed of 11.58 mm/min, and a SiC of 16.67%, respectively. For the current inquiry, the computed ultimate tensile strength and microhardness are 984 MPa and 89.9 HV, respectively, and these values are congruent with the findings of effectiveness studies. It is deduced from this study that the optimal parameters are convergent irrespective of the two used techniques for the investigated experimental data.

“…FSW can fabricate lap or butt joints for different material thicknesses and lengths, and is capable of producing high-quality, high-strength joints with little distortion. The procedure involves plunging a spinning a tool composed of a hard-wearing material, highest-temperature-resistant material into the material to be jointed and translating it straight the desirable weld zone [3] [4] [5]. The heat created by friction on the tool surface and plastic dissipation in the deforming portions of the workpieces softens the material and causes it to become plasticized.…”

Section: Introductionmentioning

confidence: 99%

Implementation of hybrid RSM-GA optimization techniques in underwater friction stir welding

El-Zathry

Gadallah

et al. 2022

J. Phys.: Conf. Ser.

Standard friction stir welding process parameters have a considerable impact on the quality of functional parts produced by underwater friction stir welding (UWFSW) with additive water. Hybrid statistical techniques may be used to optimize operating parameters in order to improve the aim function. The tensile strength (UTS)of parts fabricated with UWFSW by Al 6063 material in accordance with ASTMD638-14 tests is investigated in this study. In the construction of test specimens, three parameters were varied: rotational speed from 1000 to 1800 rpm, travel speed from 4 to 10 mm/s, and shoulder diameter from 10 to 20 mm. The response surface methodology (RSM) based central composite design (CCD) matrix for the parametric combination was constructed using a second-order polynomial fitting model. The maximum UTS of testing samples on the 201T universal testing machine (UTM) was 208.27 MPa. These process parameters are also optimized using hybrid optimization approaches such as response surface methodology- genetic algorithm (RSM-GA). RSM-GA had the highest precision of 98.99 percent, which resulted in optimal characteristics such as rotating speed 1800 rpm, travelling speed 4 mm/s, and shoulder diameter 15 mm, which resulted in a maximum tensile strength of 199.0212 MPa.