Optimization of Process Parameters in Friction Stir Welding of Aluminum 5451 in Marine Applications

Abstract

Friction stir welding (FSW) is one of the primary fabrication techniques for joining different components, and it has become popular, especially in aluminum alloy structures for marine applications. The welded joint with the friction stir process greatly depends on the process parameters, i.e., feed rate, rotational speed, and pin profile of the tool. In the current study, plates of aluminum 5451 alloy were joined by the FSW technique, and the Taguchi method was used to find the process parameters at an optimal level. The maximum value of tensile strength, i.e., 160.6907 MPa, was achieved using optimum welding conditions of a tool rotation speed of 1400, a feed rate of 18 mm/min, and the tool pin with threads. The maximum value of hardness, i.e., 81.056 HV, was achieved using optimum conditions of 1200 tool rotational speed and a feed rate of 18 mm/min with a tool pin profile having threads. In addition, the contribution in terms of the percentage of each input parameter was found by the analysis of variance (ANOVA). The ANOVA results revealed that the pin profile of the tool has the maximum contribution of 67.77% and 62.42% in achieving the optimum value of tensile strength and hardness, respectively. The study also investigated the joint efficiency of the friction stir welded joint, hardness at the weld zone, and metallography on FSW samples at the optimized level. The effectiveness and reliability of FSW joints for shipping industry applications can be observed by joint efficiency. That was investigated at optimum conditions, and it comes out to be 80.5%.

Experimental investigation and Taguchi optimization of FDM process parameters for the enhancement of tensile properties of Bi-layered printed PLA-ABS

“…Taguchi design was used to build the design of the experiment for the parameters given in table 4. Taguchi technique provides a way of effective optimal design [35,36]. The advantage of Taguchi's design includes minimizing the number of experiments and simplifying the test plan.…”

Assessing the role of friction stir welding tool shoulder profile and parameters on mechanical performance of Al5083 weld joints pre- and post-corrosion exposure

“…Different Al alloys which belong to magnesium, aluminum and copper systems were also successfully joined with Al5083 alloy by FSW [14][15][16][17][18]. In FSW, tool design which is governed by the selection of tool dimensions including shoulder to pin diameter ratio, dimensions of pin, shoulder profile, pin profile etc influence the success of the welding process [19]. Additionally, it was a well demonstrated phenomena that the shoulder profile and pin profile influence the material flow in the weld zone [20].…”

“…Additionally, it was a well demonstrated phenomena that the shoulder profile and pin profile influence the material flow in the weld zone [20]. The processing parameters such as tool rotational and travel speeds, tilt angle and the workpiece pre-heat conditions also influence the quality of the weld joint [19]. On the other hand, weld joint microstructure usually differed from the base materials and hence, a different corrosion phenomenon can be expected within the weld zone compared with the adjacent regions.…”

“…development of texture after FSW. It is a common finding in the FSW that weld joint exhibits grain refinement along with development of a clear texture due to the dynamic recrystallization during welding[19]. (111) plane is close packed plane in FCC crystal structure.…”

Role of tool shoulder profile and tool rotational speed on the mechanical performance of friction stir welded Al5083 joints

“…Tool geometry, tool rotational and traverse speeds, tool tilt angle, penetration depth, workpiece preheating condition are a few examples for the process parameters in friction stir welding which influence the joint quality [6,19]. Tool geometry consist of tool pin profile, shoulder to pin diameter ratio, pin dimensions, pin profile, shoulder surface profile [20]. The material flow within the weld zone and the recrystallization of the stirred material beneath the shoulder depend on the pin profile and the shoulder profile.…”