Karafan Journal

Karafan Journal

Investigation and optimization of friction stir welding process of aluminum 5010 to 6061

Document Type : Original Article

Authors
Peyman Ghasemi Tamami 1
Abootaleb Javadimanesh 2
Saeid Mardani 3
1 PhD Student, Department of Manufacturing, Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran.
2 Faculty Member, Department of Mechanical Engineering, Faculty of Imam Mohammad Bagher, Mazandaran Branch, Technical and Vocational University (TVU), Sari, Iran.
3 B. Sc. ,Department of Mechanical Engineering, Faculty of Imam Mohammad Bagher, Mazandaran Branch, Technical and Vocational University (TVU), Sari, Iran.
10.48301/kssa.2021.128408
Abstract
The feasibility of joining AA6061 and AA5010 by FSW is one of main purposes of the current research. First, 9 experiments were conducted with aim of optimal pin profile design. These experiments were designed by using various straight cylindrical, square and triangular pin profiles under different frictional conditions. Results of the first stage indicated that the tool with square pin profile leads to the highest tensile strength, hardness and elongation. All process steps were simulated in finite element software and the results were analyzed. Hence, this tool was applied for conducting the second stage of experiments. Experiments of second stage were designed and performed with the aim of investigating the effect of tool rotary speed, welding speed and plunge depth on tensile strength, hardness and elongation and selection of optimal factors combination which result in maximal mechanical properties. In the second stage, the central composite design of experiments was used to conduct experiments and to model mechanical properties accurately and find the optimal solution, the neural network was integrated with particle swarm optimization (PSO). Results demonstrated that the neural network with topography of 3-11-3 yields superior prediction. In addition, tool rotary speed of 800 RPM, welding speed of 60 mm/min and plunge depth of 0.2 mm is the optimal combination that leads to maximal tensile strength, hardness and elongation.
Keywords
Friction stir welding
Aluminum alloys 5010 and 6061
Finite element simulation
Optimization
References
[1] Thomas, W. M. (1991). Friction stir butt welding. Int. Patent No. PCT/GB92/02203.
[2] Asadi Boroojeni, B., & Mozafari Vanani, L. (2020). The effect of tool geometry on the tensile strength of polypropylene Components Welded by Friction Stir Welding Method. Karafan Quarterly Scientific Journal, 17(1), 143-155. https://doi.org/10. 48301/kssa.2020.112761
[3] Elangovan, K., & Balasubramanian, V. (2007). Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A, 459(1), 7-18. https://doi. org/10.1016/j.msea.2006.12.124
[4] Taban, E., Gould, J. E., & Lippold, J. C. (2010). Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: Properties and microstructural characterization. Materials & Design (1980-2015), 31(5), 2305-2311. https://doi.org/10.1016/j.matd es.2009.12.010
[5] Zhou, C., Yang, X., & Luan, G. (2006). Effect of root flaws on the fatigue property of friction stir welds in 2024-T3 aluminum alloys. Materials Science and Engineering: A, 418(1), 155-160. https://doi.org/10.1016/j.msea.2005.11.042
[6] Jayaraman, M., Sivasubramanian, R., & Balasubramanian, V. (2010). Establishing relationship between the base metal properties and friction stir welding process parameters of cast aluminium alloys. Materials & Design, 31(9), 4567-4576. https://doi.org/10.1016/j.matdes.2010.03.040
[7] Jayaraman, M., Sivasubramanian, R., Balasubramanian, V., & Lakshminarayanan, A. (2008). Prediction of Tensile Strength of Friction Stir Welded A356 Cast Aluminium Alloy Using Response Surface Methodology and Artificial Neural Network. Journal for Manufacturing Science and Production, 9(1-2), 45-60. https://doi.org/10.1515/IJMSP.2008.9.1-2.45
[8] Elangovan, K., Balasubramanian, V., & Babu, S. (2008). Developing an Empirical Relationship to Predict Tensile Strength of Friction Stir Welded AA2219 Aluminum Alloy. Journal of Materials Engineering and Performance, 17(6), 820-830. https://doi.org/10.1007/s11665-008-9240-6
[9] Rajakumar, S., Muralidharan, C., & Balasubramanian, V. (2011). Influence of friction stir welding process and tool parameters on strength properties of AA7075-T6 aluminium alloy joints. Materials & Design, 32(2), 535-549. https://doi.org/10.10 16/j.matdes.2010.08.025
[10] Ghosh, M., Kumar, K., Kailas, S. V., & Ray, A. K. (2010). Optimization of friction stir welding parameters for dissimilar aluminum alloys. Materials & Design, 31(6), 3033-3037. https://doi.org/10.1016/j.matdes.2010.01.028
[11] Koilraj, M., Sundareswaran, V., Vijayan, S., & Koteswara Rao, S. R. (2012). Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 – Optimization of process parameters using Taguchi technique. Materials & Design, 42, 1-7. https://doi.org/10.1016/j.matdes.2012.02.016
[12] Murr, L. E., Flores, R. D., Flores, O. V., McClure, J. C., Liu, G., & Brown, D. (1998). Friction-stir welding: microstructural characterization. Materials Research Innovations, 1(4), 211-223. https://doi.org/10.1007/s100190050043
[13] Mohammad Khani Haji KhajeLu, B., & Maleki, M. (2020). Experimental Investigation of Dynamic Density of Aluminum Powder under High Speed Loading. Karafan Quarterly Scientific Journal, 17(1), 157-175. https://doi.org/10.48301/kssa.2020.112762
Karafan Journal
Volume 17, Issue 4 - Serial Number 50
Technical and Engineering
Winter 2021
Pages 291-321

  • Receive Date 25 April 2020
  • Revise Date 25 December 2020
  • Accept Date 16 January 2021