Modelling and optimization of submerged friction stir welding parameters for AA6061-T6 alloy using RSM

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.

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Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.622-623.323 ◽

2012 ◽

Vol 622-623 ◽

pp. 323-329

Author(s):

Ebtisam F. Abdel-Gwad ◽

A. Shahenda ◽

S. Soher

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Welding Process ◽

Tensile Behavior ◽

Frictional Heat ◽

Welding Parameters ◽

Friction Stir ◽

Aluminum Base ◽

Tool Pin ◽

Strength And Ductility

Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.

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Effect of welding parameters in friction stir welding of dissimilar alloys AA2014 and AA7075

Materials Today Proceedings ◽

10.1016/j.matpr.2021.01.816 ◽

2021 ◽

Author(s):

Raj Kumar ◽

Vikas Upadhyay ◽

Chaitanya Sharma

Keyword(s):

Friction Stir Welding ◽

Welding Parameters ◽

Friction Stir ◽

Dissimilar Alloys

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Effect of Welding Parameters on Mechanical and Microstructural Properties of Dissimilar AA6082-AA2024 Joints Produced by Friction Stir Welding

Materials Science Forum ◽

10.4028/www.scientific.net/msf.519-521.1163 ◽

2006 ◽

Vol 519-521 ◽

pp. 1163-1168 ◽

Cited By ~ 5

Author(s):

Pasquale Cavaliere ◽

Antonio Squillace

Keyword(s):

Friction Stir Welding ◽

Testing Machine ◽

Fatigue Tests ◽

Optical Observations ◽

Control Mode ◽

Welding Parameters ◽

Microstructural Properties ◽

Amplitude Control ◽

Friction Stir ◽

Mechanical And Microstructural Properties

The effect of processing parameters on mechanical and microstructural properties of dissimilar AA6082-AA2024 joints produced by Friction Stir Welding was analysed in the present study. Different samples were produced by employing a fixed rotating speeds of 1600 RPM and by using the advancing speeds of the tool of 80 and 115 mm/min. All the welds were produced in direction perpendicular to the rolling one for both the alloys and by changing, for all the processing conditions, the alloy positioned on the advancing side of the tool. The mechanical properties of the joints were evaluated by room temperature tensile tests. Fatigue tests on the welds were carried out by using a resonant electro-mechanical testing machine under constant loading control up to 250 Hz sine wave loading. The fatigue tests were conducted in the axial total stress-amplitude control mode with R=smin/smax=0.1. The microstructural evolution of the material was analysed by optical observations of the welds cross sections and SEM observations of the fracture surfaces.

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