Sustainability-based optimization of dissimilar friction stir welding parameters in terms of energy saving, product quality, and cost-effectiveness

Nguyen, Trung-Thanh; Nguyen, Chung-Thai; Van, An-Le

doi:10.1007/s00521-022-07898-8

Cited by 14 publications

(4 citation statements)

References 54 publications

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“…Among these technologies, friction stir welding is a sustainable and green solution in terms of energy consumption and environmental impact [15][16][17][18][19]. Moreover, it is characterized by a limited set of process parameters: tool rotational speed, welding speed, axial force, and tool tilt angle, which are the main parameters that are involved in production of high-strength joints [20,21] (see Figure 1).…”

Section: Introductionmentioning

confidence: 99%

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Bella

Favaloro

Borsellino

2023

Metals

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Friction Stir Welding is a suitable solid-state joining technology to connect dissimilar materials. To produce an effective joint, a phase of optimization is required which leads to the definition of process parameters such as pin geometry, tool rotational speed, rotation direction, welding speed, thickness of the sheets or tool tilt angle. The aim of this review is to present a complete and detailed frame of the main process parameters and their effect on the final performance of a friction stir welded joint in terms of mechanical properties and microstructure. Attention was focused in particular on the connection between different aluminum alloys. Moreover, the experimental results were correlated to the development and the applications of tools which can be effectively used in the design of the manufacturing process such as finite element analyses, artificial neural networks, and statistical studies. The review also aims to be a point of reference to identify the best combinations of process parameters based on the dissimilar aluminum to be joined.

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Section: Introductionmentioning

confidence: 99%

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Bella

Favaloro

Borsellino

2023

Metals

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“…In FSW, the rotational speed of the employed tool impacts the deformation of plasticized metal by influencing the volume of generated frictional heat. Slower tool rotational speeds will generate lower volumes of heat input and insufficient reaction temperature, thereby hindering the pertinent deformation of the plasticized metal in the nugget zone [27,28], leading to the generation of defects namely channel defects and macro sized cracks in the friction stir welded joints, thereby reducing the tensile strength of the fabricated joint. At the same time, larger tool rotational speeds will lead to exaggerated stirring by the tool pin, leading to detachment of huge number of Ti particles, which will be too huge in size to get distributed evenly in the nugget zone, thereby leading to several flaws (including cracks, voids etc,) thereby degrading the strength of the fabricated joint [29].…”

Section: Impact Of Parameters Of Fsw Process On Tsmentioning

confidence: 99%

“…19 as seen in the figure 7(d), from its magnified SEM images being illustrated in the figures 7(e) and (f), we can observe honey comb like surfaces having several dents and huge depressions, revealing us the failure of this joint have undergone a brittle-ductile category of fracture. This mode of failure usually in friction stir welded joints, when the heat input was lower [17,27]. It was proven fact that whenever the heat input was lower during the FSW process, it leads to improper forging of plasticized metal and will result in generation of coarsened, strengthened precipitates of secondary phase.…”

Section: Inferences From Tensile Fractographymentioning

confidence: 99%

Optimization of parameters and formulation of numerical model employing GRA–PCA and RSM approach for friction stir welded Ti–6Al–4V alloy joints

Babu S D

et al. 2024

Mater. Res. Express

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In this work, an endeavor was made to determine the impact of the tool’s shoulder diameter, pin profile, rotational and traverse speeds on the mechanical properties of the friction stir welded namely Ti–6Al–4V alloy joints. A total of 21 experiments were carried out based on the central composite design (CCD) concept of response surface methodology (RSM). A quadratic regression based numerical model was formulated to ascertain the relationship amidst the parameters of FSW process and the mechanical properties of the fabricated Ti alloy joints. Analysis of variance (ANOVA) was employed to confirm the importance of parameters and their interactive impacts. Optimized process parameter combinations were ascertained by grey relation based analysis (GRA) was coupled together with principal component analysis (PCA), a hybrid based approach. Single score of GRG based response was determined and GRG scores were ranked for all experiments. 1st rank was attained by the experiment no. 20 possessing a GRG score of 2.9989. Optimized values of 25mm shoulder diameter having a taper cylindrical pin geometry employed at a tool traverse speed of 40 mm/min, rotational speed of 1400 rpm resulted in the generation of flaw free Ti alloy joint possessing a largest tensile strength of 809.8 MPa, yield strength of 778.7 MPa and percentage of elongation of 6.9%. SEM based fractography ofTi alloy joint specimens announced that taper cylindrical pin geometry along with 25m shoulder diameter of employed tool have an inevitable part in generating frictional heat in ideal volumes and a perfect stirring action during FSW process.

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“…In terms of energy consumption and environmental impact, friction stir welding is one of these technologies that is sustainable and environmentally friendly [15,16,17,18,19]. Additionally, it is distinguished by a restricted range of process parameters: the primary parameters involved in the creation of high-strength joints are tool tilt angle, axial force, welding speed, and tool rotational speed [20,21].…”

Section: Introductionmentioning

confidence: 99%

A Study of Process Parameters for the Friction Stir Welding of Dissimilar Aluminum Alloy

2024

IRJMETS

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A good solid-state joining technique for combining different materials is stir welding. A phase of optimization is necessary to define process parameters like pin geometry, tool tilt angle, welding speed, sheet thickness, and tool rotational speed and direction in order to produce an effective joint. The objective of this review is to provide a comprehensive and in-depth overview of the primary process parameters and their impact on the mechanical properties and microstructure of the friction stir welded joint at the end. Particular emphasis was placed on the relationship between various aluminum alloys. Additionally, there was a correlation found between the experimental results and the creation and utilization of tools like statistical studies, artificial neural networks, and finite element analyses that are useful for designing manufacturing processes. In addition, the review seeks to serve as a guide for determining the optimal ratios of process variables in relation to the different types of aluminum that need to be combined.

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Sustainability-based optimization of dissimilar friction stir welding parameters in terms of energy saving, product quality, and cost-effectiveness

Cited by 14 publications

References 54 publications

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Optimization of parameters and formulation of numerical model employing GRA–PCA and RSM approach for friction stir welded Ti–6Al–4V alloy joints

A Study of Process Parameters for the Friction Stir Welding of Dissimilar Aluminum Alloy

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