Parametric optimization of friction stir welding of Al-Mg-Si alloy: A case study

Authors

  • Nasir Khan Department of Mechanical Engineering, Amity School of Engineering and Technology, Amity University Madhya Pradesh, India
  • Sandeep Rathee Department of Mechanical Engineering, Amity School of Engineering and Technology, Amity University Madhya Pradesh, India
  • Manu Srivastav Department of Mechanical Engineering, Indian Institute of Information Technology, Design and Manufacturing, Jabalpur (IIITDM Jabalpur) Department of Mechanical Engineering, Manav Rachna International Institute of Research & Studies, Faridabad, India

DOI:

https://doi.org/10.2298/YJOR200214007K

Keywords:

Friction Stir Welding, Mechanical Properties, Al-Mg-Si Alloy, Process Parameters, Optimization, Taguchi Technique

Abstract

Al-Mg-Si alloys have wide applications in industries such as aerospace, marine, automobile, construction. In this work, newly developed friction stir welding (FSW) was utilized for joining of AA6082-T6 alloy. The effect of major FSW process variables like rotational speed, traverse speed, and shoulder diameter of tool is studied over microstructural and mechanical characteristics of friction stir welded (FSWed) joints. Experimental design was done using Taguchi method (L9 orthogonal array). Three factors viz. rotational speed, welding speed, and diameter of tool shoulder were taken at three levels each. Mathematical modelling was developed in order to optimize the tensile strength of weld joints. Analysis of variance (ANOVA) was utilized to determine the percentage contribution of input variables. The results of present study exhibits that shoulder diameter, rotation, and welding speed of tool significantly affect the mechanical strength of FSWed joints.

References

Çam, G, "Friction stir welded structural materials: beyond Al-alloys", International Materials Reviews, 56 (1) (2011) 1–48.

Cam, Gürel, Mistikoglu, Selcuk, "Recent developments in friction stir welding of Al alloys", Journal of Materials Engineering and Performance, 23 (6) (2014) 1936–1935.

Mishra, Rajiv, S., Ma, ZY, "Friction stir welding and processing", Materials Science and Engineering: R: Reports, 50 (1-2) (2005) 1-78.

Thomas, WM., "Friction stir butt welding", Int. Patent No. PCT/GB92/02203, 1991.

Rathee, Sandeep, Maheshwari, Sachin, Siddiquee, Arshad, Noor, Srivastava, Manu, "A review of recent progress in solid state fabrication of composites and functionally graded systems via friction stir processing", Critical Reviews in Solid State and Materials Sciences, 43 (3) (2018) 334–366.

Srivastava, Manu, Rathee, Sandeep, Maheshwari, Sachin, Noor, Siddiquee, Arshad, Kundra, TK., "A review on recent progress in solid state friction based metal additive manufacturing: friction stir additive techniques", Critical Reviews in Solid State and Materials Sciences, 44 (5) (2019) 345–377.

Rathee, Sandeep, Maheshwari, Sachin, Siddiquee, Arshad, Noor, Srivastava, Manu, "Friction Based Additive Manufacturing Technologies: Principles for Building in Solid State, Benefits, Limitations, and Applications", CRC Press, 2018.

Rathee, Sandeep, Maheshwari, Sachin, Siddiquee, Arshad, Noor, Srivastava, Manu, "Distribution of reinforcement particles in surface composite fabrication via friction stir processing: suitable strategy", Materials and Manufacturing Processes, 33 (3) (2018) 262–269.

Salih, Omar, S., Ou, Hengan, Sun, W., McCartney, DG., "A review of friction stir welding of aluminium matrix composites", Materials & Design, 86 (2015) 61–71.

Rai, R., De, A., Bhadeshia, HKDH., DebRoy, Tarasankar, "Friction stir welding tools", Science and Technology of Welding and Joining, 16 (4) (2011) 325–342.

Yan, Junhui, Sutton, Michael, A., Reynolds, Anthony P., "Process–structure property relationships for nugget and heat affected zone regions of AA2524–T351 friction stir welds", Science and Technology of Welding and Joining, 10 (6) (2005) 725–736.

Sameer, MD, Birru, Anil Kumar, "Mechanical and metallurgical properties of friction stir welded dissimilar joints of AZ91 magnesium alloy and AA 6082-T6 aluminium alloy", Journal of Magnesium and Alloys, 7 (2) (2019) 264–271.

Rahmatian, Behrooz, Dehghani, Kamran, Mirsalehi, Seyyed, Ehsan, "Effect of adding SiC nanoparticles to nugget zone of thick AA5083 aluminium alloy joined by using double-sided friction stir welding", Journal of Manufacturing Processes, 52 (2020) 152–164.

Kadaganchi, Ramanjaneyulu, Gankidi, Madhusudhan, Reddy, Gokhale, Hina, "Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology", Defence Technology, 11 (3) (2015) 209–219.

Antony, J., "Fundamentals of Design of Experiments", in Design of Experiments for Engineers and Scientists, J. Antony, Editor, Butterworth-Heinemann: Oxford, 2003, 6-16.

Rathee, Sandeep, Maheshwari, Sachin, Siddiquee, Arshad, N., "Issues and strategies in composite fabrication via friction stir processing: A review", Materials and Manufacturing Processes, 33 (3) (2018) 239–261.

Downloads

Published

2021-05-01

Issue

Vol. 31 No. 2 (2021)

Section

Research Articles

License

Copyright (c) 2021 YUJOR

Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.