Prediction of Tensile Strength in Friction Welding Joins Made of SA213 Tube to SA387 Tube Plate through Optimization Techniques

Abstract

In modern times, the Industry X.0 has emerged as the paradigm that has become the core of digital technology-driven business organizations. Further, this paper establishes a tube to tube plate friction welding technology with the help of deploying an external tool, also known referred to as the FWTPET scheme. Besides, the SA213 tube and SA387 tube plate were combined by employing a unique interference fit technique. Also, the strength of this combined portion was assessed with and without the aid of a holding block. Subsequently, the analytic optimization approaches like genetic algorithm, analysis of variance, and Taguchi L9 orthogonal array design were deployed in the prediction of the optimum joining strength. Moreover, the input parameters include the projection of the tube (mm), the rotational speed of the tool (rpm), and depth of cut (mm); besides, the tensile strength is considered as the output parameter. Also, the grain size distribution around the weld zone and the presence of base metal were measured through an optical microscope as per ASTM linear intercept method. Further, it is evident that grain refinement had occurred in the weld zone, which in turn increases the tensile strength. The exceptional weld strength (tensile strength) was obtained when joining of SA213 tube and SA387 tube plate through interference fit using a holding block without a hole in the tube. Experimentally, it was found that the achieved tensile strengths were 836.8 MPa (without a hole) and 789.35 MPa (with hole) using the holding block, respectively. Additionally, it was found that in the absence of a holding block, the achieved tensile strength is 762.2 MPa (without a hole), and 700.8 MPa (with a hole), correspondingly. The deviation of tensile strength between the predicted (genetic algorithm) and experimental was found minimal. Therefore, for achieving this strength, the suitable operating parameters set include the rotational speed of the tool (1300 rpm), projection of the tube (1 mm), and depth of cut (0.5 mm) with backing block configuration.

Realizing a Novel Friction Stir Processing-Enabled FWTPET Process for Strength Enhancement Using Firefly and PSO Methods

“…The new attractiveness value was calculated using Equation (5). Then, it was checked whether the new parameter values were within the range; if not, the values were normalized using Equation (8). Subsequently, PR was applied in Equation 7, which determined the output tensile strength.…”

“…It is primarily used for modifying the microstructure of near-surface layers [6]. Friction stir welding (FSW) is also used to join two metallic materials without melting the workpiece which uses a non-consumable tool similar to FWTPET [7,8]. The combined process of FWTPET and FSP was developed to join the unsymmetrical shapes of the tube and tube plate.…”

Comparative analysis of FWTPET welded austenitic alloy steel samples using transition fit approach: An investigation of mechanical, morphological, and microstructural properties

“…This experimental study uses of SA213 -T11 grade Tube and SA387 -GR91 Tube plate, both of which are seamless Ferritic and Austenitic alloy grades [10]. Tungsten carbide (WC) is an external tool used in FWTPET process, particularly in Low chrome moly steel materials that can endure the high temperatures.…”

“…The external tool used in welding is crafted from WC, primarily due to withstand at higher temperature and rigidity [10]. The tool design includes a shoulder, tool pin, and other tailored shapes to suit the speci c workpiece requirements.…”