Examination of Friction Stir-Welded AA 6262/5456 Joints through the Optimization Technique

Abstract

Friction stir welding (FSW) is the solid state welding technique which is mostly utilized to join similar and dissimilar Al, Cu, Mg, and their alloys. This research investigated that the tensile strength of FSW dissimilar Al6262 and Al5456 of 4 mm thickness is carried out using an H-13 tool pin along with different process variables such as tool rotational speed (TRS), welding speed (WS), and tool tilt angle (TTA). The selected parameters are set as TRS of 900, 1100, and 1400 rpm, WS of 20, 30, and 40 mm/min with TTA of 2, 2.5, and 3° to find out significant parameters on tensile strength (TS). The Taguchi L27 method is taken to create a number of experiments to recognize the optimal level of each parameter to accomplish the highest TS value. From the experimental results witnessed, the extreme TS (202.44 MPa) is acquired at sample 22 when maintaining TRS-1400 rpm, WS-30 mm/min, and TTA-2 degree, whereas minimum TS (165.88 MPa) is attained at sample 15 of TRS-1100 rpm, WS-30 mm/min, and TTA-3 degree. The ANOVA outcome revealed that TRS is the most significant factor (23.24%) which improves the tensile property of joints, followed by a weld speed of 21.7% and a combination of tool speed and weld speed (16.17%). The increment in the tool tilt angle does not play a vital role in improving the TS value, and MINITAB -17 software helped to find a relation between the parameters in the regression equation.

Developed Mathematical Model of Wear Rate for Al Alloy with Nanoparticle Reinforcement

“…Using ANOVA, it was determined how wear parameters such normal load, sliding speed, and distance affected the wear of the composites. measure of how much of the trial's overall difference takes into account each important variable [26,27]. Using the Taguchi technique, it is crucial to take into account both the F and P values when assessing the predictability of a particular quadratic regression model.…”

“…After the metal collection procedure, a sample of the TiC//Flyash reinforced Al5456composite is created utilising the Squeeze Casting (SC) technique. The investigations on wear test characteristics employed ASTM standard specimens [11][12][13][14]. To create things in the right shape, stir cast technique is primarily used.…”

Mechanical Property Evaluation of Stir-Squeeze Cast Al-Based Nano SiC Composites

“…This resulted in the stir casting configuration shown in Fig 1 as well as a reduced amount of slag. The stirrer was introduced to the components of the compound by means of a safe lifting mechanism [23][24][25]. First, an electric furnace was used to heat an aluminium alloy crucible to a temperature of about 800 °C.…”

Mechanical Characterization of Friction-Stir-Welded Aluminum AA7010 Alloy with TiC Nanofiber

“…Due to their lightweight and high strength, aluminium-based alloys are often welded with brass, copper [1], and other aluminium alloys to make high-performance materials with combined properties for specifc uses [2]. So far, much more research has been done to improve the quality of welds and the life of tools, both of which directly afect the overall process economy [3]. It is still hard to make signifcant welds at least 85% as strong as the metal they are attached to.…”