Modelling and Optimisation of Friction Stir Welding on AA6061 Alloy

Sankar, B. Ravi; Umamaheswarrao, P.

doi:10.1016/j.matpr.2017.07.076

Cited by 30 publications

(14 citation statements)

References 10 publications

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“…On this basis, the tool rotation speed should, to a greater extent, determine both the level of critical value of the tool pressing, and the transition nature to the second part of the dependence, which is confirmed by the data [3,5,7]. As the analysis of diagrams shows, with an increase in n the characteristic features of the transition moment to the second section AB is a decrease in the level of critical force of pressing and a more flat form of the dependence itself.…”

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confidence: 54%

“…Based on this, one of the reasons for the need to maximize heating of the edges is to increase the homogeneity of the metal when stirring and increase the metal density due to decrease in the number of cavities in the joint area [5,6]. Thus, formation of welded joints to a large extent should be determined by the peculiarities of development of the diffusion mass transfer processes, and increase in the metal heating degree is a well-founded decision [7]. Analysis of numerous studies of the internal structure of metal materials after welding joint formation according to the technology of friction stir welding indicates a qualitative coincidence in the indicators with the structural state of the metal after hot reduction.…”

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confidence: 99%

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Concept of determining the friction stir welding mode

Вакуленко¹,

Plitchenko²,

Murashova³

et al. 2018

SBNMU

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Purpose. To determine the optimal mode of friction stir welding of aluminum alloy. Methodology. 2.5 mm thick plates made of aluminum alloy AMg5 with chemical content of alloying elements within grade composition were used as a material for the research. Friction stir welding was carried out using specially designed equipment with a preselected form and dimensions of working tool. At different ratios of the working tool rotation frequency the forces of pressing and speed of its movement along the connecting edges determined the metal heating degree and the quality of welded joint formation. Temperature of the connecting edges heating was determined by thermocouples immersed in metal at different distances from the welded joint. Rotational speed of the working tool was from 800 to 1600 min -1 with the effort of pressing to the plate surface from 580 to 1370 N and the speed of movement along the joint of 50 mm/min.findings. On the basis of different ratios of the working tool rotation speed and pressing to the connecting edges, there were determined conditions for achieving the effect of constant softening during friction stir welding. In order to achieve a high level of welding joint quality during friction stir welding it is necessary to carry out the process at high revolutions of the working tool and low levels of pressing to the connecting edges.originality. At the constant speed of the working tool rotation proportional increase in alloy temperature from increasing the level of its pressing to the connecting edges is disturbed by achievement of conditions of the dynamic softening processes development.Practical value. The concept of choosing the technological parameters of welding process is determined, when it is preferred to increase in speed of the working tool rotation when the level of its pressing to the connecting edges decreases.

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confidence: 54%

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confidence: 99%

Concept of determining the friction stir welding mode

Вакуленко¹,

Plitchenko²,

Murashova³

et al. 2018

SBNMU

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“…Many recent experimental research investigations have proved that, the majority of the defects related with the joints (fabricated using traditional & conventional joining techniques) found to be eliminated completely due to the employment of FSW process, especially during joining of Al alloys [30][31][32][33][34][35][36][37][38][39][40][41]. For example, Yufeng Sun et al [31] performed an experimental investigation during joining of 6061 -T6 Al alloys using FSW process and proved that, the formation of fine grains in the stir zone have resulted in the fabrication of joints, which can withstand shear loads to a maximum of 4500 N, which is very much when compared with that of the joints fabricated using conventional welding techniques.…”

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confidence: 99%

“…The experimental analysis revealed that the geometry of the FSW tool pin plays a significant role in the generation of the banded structures when compared with that of the other FSW process parameters. Likewise, another team of researchers lead by Ravi Sankar et al [38] conducted an investigation to optimize various parameters of the FSW process including the speed, traversing speed, diameter of the FSW tool pin etc using 3 factors 5 level response surface design matrix and aimed to fabricate AA6061 Al alloy joints with improved mechanical properties including hardness. Their experimental works revealed that the fabricated joints were found to increase initially and then decline with the increase in the rotational speed.…”

Section: Survey Of Literaturementioning

confidence: 99%

Experimental investigation on the improvement of the properties of the AZ80A Mg alloy joints using friction stir welding process

Sevvel¹,

Mahadevan²,

Sateš³

et al. 2019

FME Transactions

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An experimental investigation was conducted with the basic objective of demonstrating the feasibility of joining the AZ80A Mg alloys using the technique of friction stir welding (FSW). Good quality joints free from defects were obtained for 5mm thickness AZ80A Mg alloy flat plates at a speed of rotation of 750 rpm with a traversing speed of 1.5 mm/min, by employing a FSW tool fabricated out of M35 grade High Speed Steel(HSS). It was experimetally observed that, the nugget zone (NZ) of the defect free weldments were found with fine sized, equally spaced & uniformly distributed grains when compared with that of the parent metal. Apart from this, the heat affected zone (HAZ) lying beside the NZ was found to possess larger sized near equaxied grains due to the effect of annealing. The weld zones were found to possess regions of slight softening nature when compared to that of the parent metal, arising from the dislocation of the lower densities. Moreover, the tensile strength of the defect free weldments was found to be around 78% of the parent metal, which seems to better than that of the strengths obtained using conventional joining techniques.

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“…The relationship between FSW input parameters and output variables could be specified through developing mathematical models. In this regard, artificial neural network [14,15], Taguchi optimization technique [16,17], genetic algorithm, fuzzy logic, and other optimization methods were applied [18,19]. Kumar and Murugan employed FSW to maximize tensile strength and keep the mechanical properties in welding process of Aluminum matrix composites.…”

Section: Introductionmentioning

confidence: 99%

Development of an optimal process for friction stir welding based on GA-RSM hybrid algorithm

Khansari

Berto

Karimi

et al. 2018

Frattura Ed Integrità Strutturale

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ABSTRACT. Performance of Friction Stir Welding (FSW) as a solid-state process is approved in several engineering applications, especially aluminum industries. Identification of mechanical behavior of the associated welded zone is necessary due to these extensive applications of FSW. In this study, considering the effect of rotational and forward speed of welding tool on the mechanical properties of welded region, a hybrid optimization method based on combination of Genetic Algorithm (GA) and Response Surface Method (RSM) named here as GA-RSM is proposed to achieve maximum tensile and ultimate strength. The results of GA-RSM are validated by per-forming necessary experimental tests on two wide-used 2024 and 5050 aluminum alloys. The results show that GA-RSM could be an effective approach to achieve optimized process for FSW with minimum cost.

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Modelling and Optimisation of Friction Stir Welding on AA6061 Alloy

Cited by 30 publications

References 10 publications

Concept of determining the friction stir welding mode

Concept of determining the friction stir welding mode

Experimental investigation on the improvement of the properties of the AZ80A Mg alloy joints using friction stir welding process

Development of an optimal process for friction stir welding based on GA-RSM hybrid algorithm

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