scholarly journals Experimental and thermal investigation with optimization on friction stir welding of nylon 6A using Taguchi and microstructural analysis

2021 ◽  
Vol 13 (10) ◽  
pp. 168781402110507
Author(s):  
Gajula Sri Venkata Seshu Kumar ◽  
Anshuman Kumar ◽  
S Rajesh ◽  
Rama Bhadri Raju Chekuri ◽  
Venkatesa Prabhu Sundaramurthy
Keyword(s):  
Friction Stir Welding ◽  
Feed Rate ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Composite Plates ◽  
Friction Stir ◽  
Thermal Investigation ◽  
Operating Process ◽  
Environmentally Friendly Process ◽  
Fsw Parameters

Friction stir welding is an environmentally friendly process of joining due to the non-usage of flux, or any shield gas. Therefore, this article proposes an experimental and thermal investigation with optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS), and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500, 1000, and 1500 rpm as TRS, 30, 40, and 50 mm as feed rate by varying the pitch values as 1, 2, and 3 mm. Further, the analysis of variance (ANOVA) also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively. The experimental and optimum FSW parameters for maximum UTS are obtained at a feed rate of 30 mm/min, tool pitch of 3 mm, and the TRS of 500 rpm.

scholarly journals Experimental Investigation and Optimization on Friction Stir Welding of Nylon 6A Using Taguchi and ANOVA with Microstructural Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
G. S. V. Seshu Kumar ◽  
Anshuman Kumar ◽  
S. Rajesh ◽  
Rama Bhadri Raju Chekuri ◽  
Amsalu Gosu Adigo
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Feed Rate ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Composite Plates ◽  
Friction Stir ◽  
Operating Process ◽  
Environmentally Friendly Process ◽  
Fsw Parameters

Friction stir welding is an environmentally friendly process of joining due to the nonusage of flux, or any shield gas, and it does not produce any harmful gases when compared to the joining process of fusion. Therefore, this article proposes an experimental investigation and optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS) and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500 rpm, 1000 rpm, and 1500 rpm as TRS, and 30 mm, 40 mm, and 50 mm as feed rate by varying the pitch values as 1 mm, 2 mm, and 3 mm. Further, the analysis of variance (ANOVA) is also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively.

Optimization of Process Parameters for Improved Corrosion Resistance and Microstructural Exploration in Friction Stir Welding of AA2024 - AA6061

2019 ◽  
Vol 969 ◽  
pp. 589-594
Author(s):  
R. Dinesh Kumar ◽  
D. Srija ◽  
P. Suresh ◽  
S. Muthukumaran
Keyword(s):  
Corrosion Resistance ◽  
Friction Stir Welding ◽  
Optimal Parameter ◽  
Microstructural Analysis ◽  
Traverse Speed ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Three Stages ◽  
Fsw Parameters

The aluminium alloys AA2024 and AA6061 are widely used for fabricating light weight structural member with better strength and corrosion resistance. Friction stir welding (FSW) parameters such as rotational speed, tool shoulder profile and traverse speed are used to identify the corrosion resistance and microstructural analysis in different weld region of AA2024-AA6061 dissimilar joints. In this work, Taguchi L9 orthogonal array with three variables and three stages has been used to reduce the number of experiments. Potentiodynamic polarization (PDP) testing results are optimized by ANOVA technique and obtain the corrosion rate as 5.72 mil/yr and resistance polarization as 835.28 ohm.cm2. The optimal parameter set is found to be 1000 rpm, flat shoulder and 45 mm/min. The microstructural analysis reveals localized pit dissolution in the nugget zoneThe aluminium alloys AA2024 and AA6061 are widely used for fabricating light weight structural member with better strength and corrosion resistance. Friction stir welding (FSW) parameters such as rotational speed, tool shoulder profile and traverse speed are used to identify the corrosion resistance and microstructural analysis in different weld region of AA2024-AA6061 dissimilar joints. In this work, Taguchi L9 orthogonal array with three variables and three stages has been used to reduce the number of experiments. Potentiodynamic polarization (PDP) testing results are optimized by ANOVA technique and obtain the corrosion rate as 5.72 mil/yr and resistance polarization as 835.28 ohm.cm2. The optimal parameter set is found to be 1000 rpm, flat shoulder and 45 mm/min. The microstructural analysis reveals localized pit dissolution in the nugget zone.

Effect of Friction Stir Welding Process Parameters on the Mechanical Properties of AA 6061 Aluminum Alloy Using Taguchi Orthogonal Technique

2015 ◽  
Vol 813-814 ◽  
pp. 431-437 ◽  
Author(s):  
Singarapu Ugender ◽  
A. Kumar ◽  
A. Somi Reddy
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Optimization Technique ◽  
Friction Stir ◽  
Tool Tilt Angle ◽  
Fsw Parameters

In this investigation, the effect of friction stir welding (FSW) parameters such as D/d ratio, tool tilt angle and welding speed on the mechanical properties of tensile strength, and impact energy of AA 6061 alloy was studied. The experiments were carried out as per Taguchi parametric design concepts and an L9 orthogonal array was used to study the influence of various combinations of process parameters. Statistical optimization technique, ANOVA was used to determine the optimum levels and to find the significance of each process parameter. The results indicate that D/d ratio, welding speed are the most significant factors, followed by tool tilt angle in deciding the mechanical properties of friction stir welding aluminum alloy.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

Microstructure and Mechanical Properties at the Unsteady Areas of Non-Linear Friction Stir Welding

2007 ◽  
Vol 561-565 ◽  
pp. 1059-1062 ◽  
Author(s):  
H. Takahara ◽  
Masato Tsujikawa ◽  
Sung Wook Chung ◽  
Y. Okawa ◽  
Kenji Higashi
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Parameter ◽  
Butt Joints ◽  
Friction Stir ◽  
Non Linear ◽  
Linear Friction ◽  
Fsw Parameters ◽  
Five Axis ◽  
Welding Direction

The influence of tool control in non-linear friction stir welding (FSW) on mechanical properties of joints was investigated. FSW is widely applied to linear joints. It is impossible for five axis FSW machines, however, to keep all the FSW parameters in optimum conditions at non-linear welding. Non-linear FSW joints should be made by compromise with the order of priority for FSW parameters. The tensile test results of butt joints with rectangular change in welding direction on plate plane (L-shaped butt joints) with various welding parameter change. It was found that turn to the retreating side is encouraged when welding direction change. And the method of zero inclination tool angle is effective at non-linear and plane welding.

Effect of plasma preheating on weld quality and tool life during friction stir welding of DH36 steel

2021 ◽  
pp. 095440542199013
Author(s):  
Avinish Tiwari ◽  
Pardeep Pankaj ◽  
Saurav Suman ◽  
Piyush Singh ◽  
Pankaj Biswas ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Force Measurement ◽  
Deep Understanding ◽  
High Strength ◽  
Microstructural Characterization ◽  
Stir Zone ◽  
Friction Stir ◽  
Allotriomorphic Ferrite ◽  
Fsw Parameters

Friction stir welding (FSW) of high strength materials is challenging due to high tool cost and low tool life. To address this issue, the present investigation deals with an alternative of plasma-assisted friction stir welding (PFSW) of DH36 steel with WC-10%Co tool. Plasma preheating current (13 A, 15 A, and 17 A) was varied by keeping other FSW parameters as constant. During the FSW and PFSW process, force measurement and thermal history aided in a deep understanding of the process, tool degradation mechanisms, accompanied by the mechanical and microstructural characterization of the welded joints. The stir zone hardness was increased from 140 HV0.5 to about 267 HV0.5. The yield and tensile strength of weld increased from 385 MPa and 514 MPa to about 391 MPa and 539 MPa, respectively. Weld joint elongation (%) was increased from ~10% of weld 1 to ~13.89% of weld 4. During PFSW, the process temperature was increased, the cooling rate was lowered, and the weld bead was widened. The results also revealed that the plasma-assisted weld resulted in polygonal ([Formula: see text]) and allotriomorphic ferrite as the major constituents in the stir zone. Pearlite dissolution and spheroidization were observed in the ICHAZ and SCHAZ, respectively. Additionally, the plasma preheating reduced the tungsten tool’s wear by 58% compared to FSW.

A study on the effect of cooling on microstructure and mechanical properties of friction stir-welded AA5086 aluminum butt and lap joints

2017 ◽  
Vol 233 (6) ◽  
pp. 1156-1165 ◽  
Author(s):  
Adel Sedaghati ◽  
Hamed Bouzary
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Feed Rate ◽  
Rotational Speed ◽  
Lap Joints ◽  
Tensile Behavior ◽  
Water Cooling ◽  
Friction Stir ◽  
Microstructural Behavior ◽  
Constant Feed Rate

In this paper, the effect of water cooling on mechanical properties and microstructure of AA5086 aluminum joints during friction stir welding is investigated. For doing so, the mechanical and microstructural behavior of samples welded both in air and in water was analyzed. Tests were performed involving both butt and lap welds and the results were compared. The effect of rotational speed at constant feed rate of 50 mm/min and changing rotational speed ranging from 250 to 1250 r/min was investigated. The results showed a significant change in the tensile behavior of the butt-welded specimens due to water cooling. In addition, welding was performed at constant spindle speed of 800 r/min and various traverse speeds (25 mm/min to 80 mm/min) to determine the effect of feed rate. The strength increases at first, but then decreases dramatically along with the feed rate which is due to the occurrence of a groove defect. Results showed some generally positive impacts of water cooling which are discussed in terms of tensile results, hardness distributions and microstructure analysis.

scholarly journals Thermo-mechanical analysis of linear welding stage in friction stir welding - influence of welding parameters

2021 ◽  
pp. 186-186
Author(s):  
Darko Veljic ◽  
Marko Rakin ◽  
Aleksandar Sedmak ◽  
Nenad Radovic ◽  
Bojan Medjo ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Welding Speed ◽  
Reaction Force ◽  
Material Model ◽  
Element Model ◽  
Welding Parameters ◽  
Al Alloy ◽  
Friction Stir ◽  
Fsw Parameters

The influence of friction stir welding (FSW) parameters on thermo-mechanical behaviour of the material during welding is analysed. An aluminium alloy is considered (Al 2024 T351), and different rotating speed and welding speed are applied. Finite element model consists of the plate (Al alloy), backing plate and welding tool, and it is formed and solved in software package Simulia Abaqus. The influence of the welding conditions on material behaviour is taken into account by application of the Johnson-Cook material model. The rotation of the tool affects the results: if increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, the plastic deformation of the material, is negligibly changed. When the welding speed is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming increases. Combined, these two effects cause small change of the total heat generation. For the same welded joint length, the plate welded by lower speed will be heated more intensively. The changes of the heat generation influence both the temperature field and reaction force, which are also considered.

A Study on Friction Stir Welding Process for AA2219/AA2195 Joints

2018 ◽  
Vol 762 ◽  
pp. 339-342
Author(s):  
Ho Sung Lee ◽  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon
Keyword(s):  
Friction Stir Welding ◽  
Welded Joints ◽  
Rotation Speed ◽  
Microstructural Analysis ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Manufacturing Cost ◽  
Significant Saving ◽  
Friction Stir ◽  
Rotation Direction

The object of this study was to study mechanical properties of friction stir welded joints of AA2219 and AA2195. AA2219 has been used as an aerospace materials for many years primarily due to its high weldability and high specific strength in addition to the excellent cryogenic property so to be successfully used for manufacturing of cryogenic fuel tank for space launcher. Relatively new Aluminum-Lithium alloy, AA2195 provides significant saving on weight and manufacturing cost with application of friction stir welding. Friction stir welding is a solid-state joining process, which use a spinning tool to produce frictional heat in the work piece. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool, and the experiment was conducted under the condition that the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. Tensile tests were conducted to study the strength of friction stir welded joints and microhardness were measured with microstructural analysis. The results indicate the failure occurred in the relatively weaker TMAZ/HAZ interface of AA2219. The optimum process condition was obtained at the rotation speed of 600-800 rpm and the travelling speed of 180-240 mm/min.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

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