Evaluating the tensile strength of friction welded (AA6061 &amp; AA7075-T6) dissimilar joints by using response surface methodology

Bakkiyaraj, M.; Palanisamy, Ponnusamy; Balasubramanian, V.

doi:10.1088/2053-1591/ab1baa

Cited by 14 publications

(9 citation statements)

References 22 publications

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“…e developed numerical model is at a satisfactory level since the obtained model p value is 0.0002 with an F value of 88.89. Furthermore, the terms relating to the empirical model such as F, P, FT, F 2 , T 2 , and P 2 are identified at a substantial level as their values fall (less than 0.05) in the permissible limits [22][23][24]. Meanwhile, the R 2 predicted and adjusted values are found to have a reasonable agreement with each other since their 2…”

Section: Evaluation Of Statistically Developed Modelmentioning

confidence: 88%

“…is Box-Behnken design-based investigation has 3 middle points and 12 outside points. e variables such as friction load (f), friction time (t), and upset load (p) are the important parameters [17,18,22], and these have been rotated to generate the design matrix in accordance with process windows. Meanwhile, the rotation speed is kept constant at 1800 rpm for all 15 sets of experiments.…”

Section: Rsm and Experimentationmentioning

confidence: 99%

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Influence of Process Parameters on Tensile Strength of the Friction Welded AA6063-T6 Joints by Box–Behnken Design Approach

Bakkiyaraj¹,

Gnanasekaran²,

Chelladurai³

et al. 2022

Advances in Materials Science and Engineering

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The present investigation demonstrates the friction welding of the AA6063-T6 joint to attain the maximum tensile strength by optimizing the parameters (friction load, friction time, and upset load) through response surface methodology. Box–Behnken design is a subset of the response surface methodology (RSM) which was employed to design the experiment numbers, and it was restricted to 15 sets. Furthermore, the inbuilt ANOVA technique was used to obtain the statistical data for the developed numerical model, and the relationship among the parameters against the output response (tensile strength) was interpreted by using the statistical data. Following this, the mechanical and metallurgical studies were done on the optimized conditions using appropriate testing and characterization equipment. The optimized conditions such as friction load (f) of 3 kN along with friction time (t) of 6 s and an upset load of 2.5 kN are given as input to attain the highest TS of 248 MPa. Moreover, the interface between the weld zone and the base metal of the joint was found to be broken during the tensile test when the friction load was given as 3 kN and 4 kN, while the fracture location of the joint was found in the weld zone at the lower friction load of 2 kN. Finally, the acquired results of the optimized friction welded conditions on the AA6063-T6 joint were discussed to justify the statistical data of the numerical model, and the same results were compared to the previous research studies.

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Section: Evaluation Of Statistically Developed Modelmentioning

confidence: 88%

Section: Rsm and Experimentationmentioning

confidence: 99%

Influence of Process Parameters on Tensile Strength of the Friction Welded AA6063-T6 Joints by Box–Behnken Design Approach

Bakkiyaraj¹,

Gnanasekaran²,

Chelladurai³

et al. 2022

Advances in Materials Science and Engineering

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“…marks (see illustration). In crystallography, this kind of fracture propagates along low-index crystallographic planes has low energy [35][36][37][38] and is brittle. A microcrack developed at the graphite-matrix contact that encircled the nodule and subsequently spread to the matrix can also be observed in the micrographs.…”

Section: Microhardness Characterizationmentioning

confidence: 99%

Experimental Investigation on Microstructure and Mechanical Properties of Friction Welded Dissimilar Alloys

Negemiya¹,

Gnanasekaran²,

Bakkiyaraj³

et al. 2022

Advances in Materials Science and Engineering

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High-temperature dissimilar connections built of Inconel 718 and AISI 410 martensitic stainless steel (MSS) are widely used in a range of industries, including boiler construction, the chemical industry, aerospace, and nuclear. When compared to other materials, Inconel 718 and AISI 410 martensitic stainless steel offer superior strength and corrosion resistance under a variety of environmental conditions. The rotational speed was adjusted between 1100 and 1500 RPM, while the friction pressure, friction time, forging pressure, and forging duration were all kept constant during the testing. Five sets of testing were performed, with the resultant tensile strength (both room temperature and hot tensile) and Vickers Hardness being recorded for each set of trials. To assess the structural integrity of the joints, a detailed microstructural investigation, SEM-EDS, and XRD were performed at their interfaces. Mechanical properties were revealed to be high at 1300 RPM due to the small grain size at the interface region; ultimate tensile strength and hardness were determined to be 571 MPa and 423 HV, respectively, due to the small grain size at the interface region. Additionally, a pitting corrosion study has been conducted on dissimilar welded joints at optimum conditions, and their results were discussed and compared with base metals.

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“…The microstructure is viewed after sectioning the joint and placed in the electronic microscope to obtain the details of the grain structure elongation in different zones. Bakkiyaraj et al [5] and Karthikeyan et al [6] deployed the response surface methodology (RSM) for the validation and optimization of process parameters of FSSW. Other notable works carried out by researchers in the FSSW can be found in [7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Parameter optimization and microstructure evaluation of welding of structural steel 1020 and AA6062

Kumar

Jayakumar

Bharathiraja

et al. 2023

Mater. Res. Express

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AA6062 and ST1020 materials are used to perform friction stir spot welding (FSSW). In this experiment, the mechanical and microstructural characteristics of the welded joint were determined using a square-head tip tool. To enhance the life of the welded joint, three essential process parameters, namely tool speed, dwell time, and plunge depth were employed with four levels. The L16 orthogonal array was adapted for experimental work to develop a process parameter table. A tensile test was performed for a larger better value to predict the strength of the welded joint, and the value is 5.65 kN. The outcome shows that dwell time is a more prominent parameter than tool speed and plunge depth. The optimal combination of welding parameters is a dwell time of 24 s, a tool rotational speed of 1200 rpm, and a plunge depth of 0.8 mm; dwell time contributes 39.66%, followed by a plunge depth 35.7%, and at last, tool speed 6.171%. Furthermore, to determine the optimum level of parameters. The microstructure of this joint was observed with respect to heat dissipation and changes in grain size. Microstructure studies were carried out to see the area under stir zone for workpieces with high and low tensile strength. This work was validated using the response surface method (RSM). The RSM results are very close to the experimental results.

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Evaluating the tensile strength of friction welded (AA6061 & AA7075-T6) dissimilar joints by using response surface methodology

Cited by 14 publications

References 22 publications

Influence of Process Parameters on Tensile Strength of the Friction Welded AA6063-T6 Joints by Box–Behnken Design Approach

Influence of Process Parameters on Tensile Strength of the Friction Welded AA6063-T6 Joints by Box–Behnken Design Approach

Experimental Investigation on Microstructure and Mechanical Properties of Friction Welded Dissimilar Alloys

Parameter optimization and microstructure evaluation of welding of structural steel 1020 and AA6062

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