Examination and Optimization of Friction Stir Welding Process Parameters of AA6092 Alloys

Jamaludeen, Umar Mohamed

doi:10.1590/0104-9224/SI29.07

Umar Mohamed Jamaludeen

conceptualization

data curation

formal analysis

investigation

methodology

resources

software

supervision

validation

writing

original draft

writing

review & editing

Annamalai Polytechnic College, Department of Mechanical Engineering, Chettinad, Tamil Nadu, India.

https://orcid.org/0000-0002-2082-191X

E-mail: umarmjamaludeen@gmail.com (UMJ)

Figures (16)
Tables (10)

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Figure 1
Details of FSW tool geometry. (a) 2-D Drawing of FSW tool; (b) Photograph of FSW tool.

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Figure 2
Schematic representations of specimen preparation for tensile test, microstructure, and hardness test on FS welded sample.

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Figure 3
Flow chart for both numerical and graphical optimization process of Design-Expert Software.

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Figure 4
Perturbation plot (influence of FSW process parameters on the UTS).

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Figure 5
Contour plots (influence of TRS and WS on UTS of FSW Joint.

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Figure 6
Contour plots (influence of TRS and AL on UTS of FSW Joint.

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Figure 7
Contour plots (influence of WS and AL on UTS of FSW Joint.

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Figure 8
Perturbation plot (influence of FSW parameters on WNH).

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Figure 9
Contour plots (influence of TRS and WS on WNH.

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Figure 10
Contour plots (influence of TRS and AL on WNH.

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Figure 11
Contour plots (influence of WS and AL on WNH.

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Figure 12
Hardness survey analysis for Optimum Conditions (TRS of 1451.67 rpm, WS of 42.22 mm/min, and AL of 5.29 kN).

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Figure 13
Contour plot (a-c), overlay plot (d-f), and prediction plot for UTS and WNH.

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Figure 14
(a) Microstructural analysis of base material, (b) Macrostructural analysis of FS welded alloy and (c-e) Microstructural analysis of FS welded alloy.

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Figure 15
(a-d) SEM analysis of base material and FS welded alloy.

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Figure 16
(a-c) SEM Fractographic analysis for the tensile specimen of FSW joint.

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Table 1
Chemical Composition of tool steel H13.

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Table 2
The level of process parameter.

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Table 3
Design matrix for FSW for AA6092.

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Table 4
Experimental Design matrix and Results of UTS and WNH.

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Table 5
ANOVA results for Ultimate Tensile Strength (UTS).

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Table 6
ANOVA results for Weld Nugget Hardness (WNH).

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Table 7
Optimization criteria used in this work.

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Table 8
Optimized FSW process parameters and responses predicted by design expert software.

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Table 9
Experimental and Predicted values for seventeen runs.

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Table 10
Validation of test results.

Elements	Cr	Mo	Si	V	C
Content (%)	4.75-5.50	1.10-1.75	0.80-1.20	0.80-1.20	0.32-0.45
Elements	Ni	Cu	Mn	S	P
Content (%)	0.3	0.25	0.20-0.50	0.03	0.03

FSW Process Parameters	Low	Medium	High
Tool Rotational Speed (rpm)	1000	1500	2000
Welding Speed (mm/min)	25	32.5	50
Axial Load (kN)	4	5	6

Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)
1	1500	25	5
2	1500	37.5	5
3	2000	37.5	6
4	1000	50	5
5	2000	25	5
6	1500	25	4
7	1500	37.5	4
8	1000	37.5	6
9	1000	37.5	5
10	1500	37.5	6
11	1500	37.5	5
12	1500	50	6
13	1500	50	5
14	2000	25	4
15	1500	37.5	5
16	1000	37.5	4
17	2000	50	5

Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)	Tensile strength (MPa)	Weld Nugget Micro-hardness (HRB)
1	1500	25	5	466	153
2	1500	37.5	5	465	152
3	2000	37.5	6	450	127
4	1000	50	5	452	142
5	2000	25	5	436	138
6	1500	25	4	458	143
7	1500	37.5	4	443	151
8	1000	37.5	6	452	141
9	1000	37.5	5	454	142
10	1500	37.5	6	466	153
11	1500	37.5	5	464	144
12	1500	50	6	466	152
13	1500	50	5	468	151
14	2000	25	4	456	123
15	1500	37.5	5	465	150
16	1000	37.5	4	454	146
17	2000	50	5	465	132

Source	Sum of Squares	df	Mean Square	F-value	p-value
Model	930.93	9	103.44	1.71	0.2454	not significant
A-Tool Rotational Speed	3.12	1	3.12	0.0517	0.8266
B-Welding Speed	18.00	1	18.00	0.2979	0.6021
C-Axial Load	66.13	1	66.13	1.09	0.3303
AB	240.25	1	240.25	3.98	0.0864
AC	4.00	1	4.00	0.0662	0.8043
BC	56.25	1	56.25	0.9310	0.3668
A²	384.01	1	384.01	6.36	0.0398
B²	77.85	1	77.85	1.29	0.2937
C²	39.17	1	39.17	0.6483	0.4472
Residual	422.95	7	60.42
Lack of Fit	413.75	3	137.92	59.96	0.0009	significant
Pure Error	9.20	4	2.30
Cor Total	1353.88	16

Source	Sum of Squares	df	Mean Square	F-value	p-value
Model	1217.69	9	135.30	7.04	0.0087	significant
A-Tool Rotational Speed	325.12	1	325.12	16.91	0.0045
B-Welding Speed	12.50	1	12.50	0.6503	0.4465
C-Axial Load	0.1250	1	0.1250	0.0065	0.9380
AB	9.00	1	9.00	0.4682	0.5158
AC	20.25	1	20.25	1.05	0.3389
BC	0.0000	1	0.0000	0.0000	10.000
A²	742.00	1	742.00	38.60	0.0004
B²	0.0026	1	0.0026	0.0001	0.9910
C²	76.95	1	76.95	4.00	0.0855
Residual	134.55	7	19.22
Lack of Fit	127.75	3	42.58	25.05	0.0047	significant
Pure Error	6.80	4	1.70
Cor Total	1352.24	16

Process Parameters / Responses	Goal	Minimum Limit	Maximum Limit	Importance
Tool Rotational Speed	is in range	1000	2000	3
Welding Speed	is in range	25	50	3
Axial Load	is in range	4	6	3
Tensile Strength	maximize	436	468	5
Hardness	maximize	123	153	5

Sample	Tool rotational speed (rpm)	Welding Speed (mm/min)	Axial load (kN)	UTS (MPa)	Microhardness HRB
1	1451.67	42.22	5.29	465.6	151.8

Run	UTS (MPa)			WNH (HRB)
Run	Experimental Value	Predicted Value	Error in %	Experimental Value	Predicted Value	Error in %
1	466	466.25	0.054	153	154.625	1.06
2	465	467.25	0.484	152	153.25	0.82
3	450	447.75	-0.500	127	128.75	1.38
4	452	455.75	0.830	142	141.75	-0.18
5	436	438.5	0.573	138	139.75	1.27
6	458	454.	-0.873	143	141.5	-1.05
7	443	444.2	0.271	151	151.75	0.50
8	452	453.2	0.265	141	139.4	-1.13
9	454	455.2	0.264	142	144.4	1.69
10	466	467.2	0.258	153	154.75	1.14
11	464	465.2	0.259	144	152.4	5.83
12	466	468.25	0.483	152	154.5	1.64
13	468	468.5	0.107	151	150.25	-0.50
14	456	457.25	0.274	123	122.25	-0.61
15	465	478.25	2.849	150	151.25	0.83
16	454	456.75	0.606	146	147.75	1.20
17	465	467.75	0.591	132	131.75	-0.19

Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)	UTS (MPa)		Error in %	Weld Nugget Hardness (HRB)		Error in %
Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)	Actual value	Predicted value	Error in %	Actual value	Predicted value	Error in %
1	1451.67	42.22	5.29	464	465.6	-0.34	154	151.8	-0.33
2	1451.67	42.22	5.29	466	465.6	0.086	153	151.8	0.32
3	1451.67	42.22	5.29	467	465.6	0.30	153	151.8	0.99

[1] E-mail: umarmjamaludeen@gmail.com (UMJ)

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Examination and Optimization of Friction Stir Welding Process Parameters of AA6092 Alloys

Abstract