Modeling and Optimization of Friction Stir Welding Parameters for Joining Dissimilar Aluminum Alloys

Elnabi, Mohamed Mohamed Abd; Osman, T. A.; Mokadem, Alaa Eldeen El; Elshalakany, Abou Bakr

doi:10.21467/ajgr.4.1.1-14

Cited by 13 publications

(5 citation statements)

References 18 publications

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“…Abolusoro et al [27] 7075-T651 / 6101-T6 (6mm) L16OA-4 2 √ 63 √ 37 85.5 28.18 √ 13.46 √ 6.43 94 Tamjidy et al [29] AA6061-T6/ AA7075-T6 Pate et al [30] AA2024/ AA6061 (4mm)…”

Section: 5mentioning

confidence: 99%

“…The optimization of FSW parameters secures the optimum properties of the joints. Optimization of the parameters has been conducted using various methods, such as the design of experiments (DOE) [4] , response surface methodology (RSM) [2] , fuzzylogic technique [75] , and artificial neural network [76] . The DOE technique has been used to optimize the FSW parameters as it minimizes time and costs through a few trials.…”

Section: Introductionmentioning

confidence: 99%

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An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

2022

J Mod Ind Manuf

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Objective: This study aims to rank friction stir welding parameters using the analytic hierarchy process (AHP). Methods:The proposed approach includes two phases to achieve a general ranking of the parameters through the separate estimation of their weights on each metal type and aggregation. The criteria used in the AHP for ranking are the contribution percentages and the degrees of the parameters obtained from the analysis of variance of experimental studies. The data were obtained from literature that used the design of experimental arrays to optimize these parameters on multiple properties and many similar and dissimilar metals. Fourteen parameters were assigned in the present analysis, namely rotational speed (RS), traverse speed (TS), axial force (AF), pin profile (PP), tilt angle (TA), the ratio between shoulder diameter and pin diameter (D/d ratio), shoulder diameter (SD), pin diameter (Pd), plunge depth (PD), pin length (PL), tool offset (TO), shoulder concavity (SC), number of passes (NOP) and base metal side (BMS). Results:The parameters were classified into highly significant, moderately significant, and insignificant based on their rankings. The RS, TS, TA, and PP were the highest-ranking parameters with a total contribution of 83.4% to outputs. The insignificant parameters included the D/d ratio, BMS, SC, AF, and Pd, with a low total contribution of 14%. The moderately significant parameters were the TO, NOP, SD, PD, and PL. Conclusion:The above-mentioned significant parameters could be controlled to maximize the response. The failure to achieve the target specified in the standard by controlling only highly significant parameters signifies a need for further modification of the FSW process. Therefore, parameters of moderate significance are potential parameters that need to be controlled to achieve the target. To limit the selection between these parameters, reference should be made to the type of metal used and then the parameters with the greatest impact on the metal are selected, i.e. controlling PL for aluminum, NOP, and SD for magnesium, and TO for aluminum-to-steel and aluminum-to-copper.

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“…Abolusoro et al [27] 7075-T651 / 6101-T6 (6mm) L16OA-4 2 √ 63 √ 37 85.5 28.18 √ 13.46 √ 6.43 94 Tamjidy et al [29] AA6061-T6/ AA7075-T6 Pate et al [30] AA2024/ AA6061 (4mm)…”

Section: 5mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

2022

J Mod Ind Manuf

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“…Tool design and machine parameters influence the stirring quality in the weld zone [5]. Recently, FSW has been used to join various metal combinations, e.g., dissimilar aluminum alloys [6,7], aluminum to brass/copper [8,9], aluminum to steel [10,11], aluminum to magnesium [12], and aluminum to titanium [13].…”

Section: Introductionmentioning

confidence: 99%

Optimization of process parameters for friction stir welding of dissimilar aluminum alloys using different Taguchi arrays

Elnabi

Mokadem

Osman

2022

Int J Adv Manuf Technol

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A statistical optimization based on experimental work was conducted to consider ultimate tensile strength (UTS) and elongation of dissimilar joints between AA5454 and AA7075 by friction stir weld (FSW). The goal of this work is to develop a comparative study of the optimization of FSW parameters using different orthogonal arrays, i.e., L12 and L16. Four parameters correlated to softening and forging requirements (rotational speed, traverse speed, tilt angle, and plunge depth), one parameter associated with the location of base metal in the dissimilar joint, and two parameters related to an FSW tool (pin profile and Dshoulder/dpin ratio) were considered and arranged in the employed arrays. Moreover, the investigation explored the microstructure and fractography of dissimilar joints and base metals by using optical and scanning electron microscopes. The results showed that the L16OA is more accurate than L12OA for the optimization of seven parameters due to the small statistical errors. For UTS, the errors range from 0.78 to 24% for L16OA and from 27.23 to 44.14% for L12OA. For elongation, the errors run from 11 to 12.9% for L16OA and from 33.77 to 49.73% for L12OA. The accuracies of generated models range from 50 to 99.5% for L16OA and range from 30.7 to 94.9% for L12OA. Tightening the levels (narrow domain) is the main reason for switching some optimum levels between both arrays. The highest UTS obtained is 221 MPa based on the optimum levels attained from L16OA, and the highest elongation is 12.83% according to the optimum levels acquired from L12OA. Despite the deficiency of effective intermixing, the study revealed that FSW acceptably could assemble joints between AA5454 and AA7075, presenting the proficiency of FSW with welding dissimilar aluminum alloys.

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“…FSW overcomes many of the problems associated with traditional joining, in particular FSW produces high-quality welds in difficult-to-weld materials such as aluminium; so it is rapidly becoming the preferred choice for manufacturing lightweight transport structures, such as boats, trains, and aircraft [7]. In addition, FSW eliminates many shortcomings such as shrinkage, solidification cracking, and porosity of fusion welding techniques [8]. FSW is particularly appropriate for aluminium alloys -which often cannot be easily joined using standard welding methods -and hence initial research efforts have been concentrated on these alloys [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Effect of Friction Stir Forming Parameters and Heat Treatment on Mechanical Properties of Fibre-Reinforced Aluminium Alloy

Tabatabaei

Ohashi

Nishihara

2022

KEM

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Fibre-reinforced materials have garnered attention due to their significant properties such as abrasion and heat resistance, as well as specific strength, which can result in environmental conservation and improved mechanical properties that can solve the limitation of developing light-weight constructions. A new method of joining stainless steel strands with an aluminium alloy using friction stir forming has recently been developed in our laboratory. In present study, the influence of the process parameters on the mechanical properties of a fibre-reinforced aluminium alloy using friction stir forming was investigated. In particular, the effect of process parameters on microstructure, hardness, and tensile properties of A5083 and A6061 alloys was evaluated. The highest tensile strength was observed at 880 and 1,240 rpm, whereas for lower rotation speeds (440 and 620 rpm), the strength decreased due to low temperatures and lower heat input. Heat treatments were applied to improve the mechanical properties of the developed A6061 fibre-reinforced composite. The effects of process parameters and heat treatment conditions on mechanical properties were experimentally investigated, and it revealed improved mechanical properties after applying T6 and age hardening treatments. It was confirmed that the strength after the heat treatment of A6061 was higher than that of the base material (310 MPa), and a high strength of 345 MPa was obtained at a rotation speed of 1240 rpm. It was concluded that rotational speed and heat treatment conditions significantly affect the metal microstructure and mechanical properties of the joint.

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Modeling and Optimization of Friction Stir Welding Parameters for Joining Dissimilar Aluminum Alloys

Cited by 13 publications

References 18 publications

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

Optimization of process parameters for friction stir welding of dissimilar aluminum alloys using different Taguchi arrays

Effect of Friction Stir Forming Parameters and Heat Treatment on Mechanical Properties of Fibre-Reinforced Aluminium Alloy

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