Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

Abstract

<jats:sec> <jats:title content-type="abstract-subheading">Purpose</jats:title> <jats:p>Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal.</jats:p> </jats:sec> <jats:sec> <jats:title content-type="abstract-subheading">Design/methodology/approach</jats:title> <jats:p>In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated.</jats:p> </jats:sec> <jats:sec> <jats:title content-type="abstract-subheading">Findings</jats:title> <jats:p>The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (<jats:italic>R</jats:italic><jats:sup>2</jats:sup>) value of 0.9759 and model <jats:italic>F</jats:italic>-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function.</jats:p> </jats:sec> <jats:sec> <jats:title content-type="abstract-subheading">Originality/value</jats:title> <jats:p>Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.</jats:p> </jats:sec>

Optimizing the Mean and Variance of Bead Geometry in the Wire + Arc Additive Manufacturing Using a Desirability Function Method

“…This study designed and performed a total of 20 experimental points of 8 factorial, 6 axial, and 6 center points using CCD. Panaskar and Terkar [12] used CCD to optimize the friction stir welding process parameters for AA6063-ETP copper welding. As input variables in the CCD process, they used the tool rotational speed, tool traverse speed, and thickness of the inter-pillar zinc foil, and the experiment was performed by constructing 60 experimental points according to the CCD process.…”

Experimental and Numerical Investigation of 2A16 Aluminum and Pure Copper Magnetic Assisted Dissimilar Laser Wire Feed Welding Brazing

“…Up to now, many researchers pay much attention to welding methods, optimizing process parameters and etc to improve the performance of Al/Cu joining component, such as ultrasonic spot welding [8][9][10], explosive welding [11][12], friction stir welding [13][14][15][16] and laser welding [17][18][19][20][21], that have been applied in various industrial production. But the formation of the representative brittle phase of (intermetallic compounds) IMC is inevitable, which causes a seriously degradation of weld properties and large melt point difference [22].…”

Analysis of the residual stresses and deformations during the autogenous GTAW process

“…The weldments may fail especially from this part. Some other researchers investigated different aspects of several welding processes (Panaskar and Terkar, 2020;Bade et al, 2020;Totemeier et al, 2006;Liu and Chung, 2018;Fang and Chan, 2018;Su et al, 2020).…”