Abstract
In this investigation central composite design (CCD) technique and mathematical model was developed by response surface methodology with three parameters, four levels and 20 runs, was used to develop the relationship between the FSW parameters (rotational speed, traverse speed, and tilt angle) and the responses (tensile strength, % Elongation, micro-hardness and residual stress) of dissimilar aluminum alloys AA5083 and AA6082 were established. The maximum tensile strength (214 MPa) was found at tool rotation speed 1300 rpm, traverse speed 45 mm/min with tilt angle 10. The maximum micro-hardness (86 HV) was found at tool rotation speed 1300 rpm, traverse speed 45 mm/min with tilt angle 10. The minimum tensile strength (161 MPa) was observed at tool rotation speed 1000 rpm, traverse speed 30 mm/min with tilt angle 20. In addition, a numerical model and empirical relationship was developed by design expert software between processing parameters (tool rotation speed, traverse speed, and tilt angle) and response surface parameters (tensile strength, percentage elongation and micro-hardness at nugget zone) and the optimized value of tensile strength, % elongation, micro-hardness, and residual stress were observed as 187.6 MPa, 19.93, 78.39 HV and 22.02 MPa respectively
Welding is a precise, reliable and cost effective technique used for joining of ferrous and non-ferrous metals. It is widely used because of the high strength of the welded joint when compared to other joining methods like riveting, fastening, adhesive bonding. Welding is an indispensable joining technology (for both fabrication and repair works) used in manufacturing industries, such as automotive, aerospace, ship building, power generation, petroleum production and refining, construction and farm equipment, electronics, and medical devices. The friction stir welding (FSW) is an energy efficient, and eco-friendly solid state welding process invented in 1991 in England as shown in fig.1.
The effect of welding parameters on the
structure and properties of the nugget zone in AA7010 was investigated and it was
found that there is an optimum rotational speed, for a given traverse speed,
that gives the highest strength and ductility for the nugget zone. As the
traverse speed is increased, it is necessary to increase the rotational speed
to maintain this optimum condition. For a given traverse speed, there is a
significant variation in grain size and hardness from the top to the bottom of
the welds [1]. Martial flow in the weld zone is non symmetrically side
distributed about the weld line because the material flow during friction stir
welding is mainly controlled by both advancing and rotating speeds [2]. The
optimal processing parameters for producing a defect free weld when a rotating
threaded weld tool is inserted into a weld and literally stirs the edges of the
seam together. The lead wire embedded in the weld seam as a tracer. At the
welding temperature of aluminum, the lead becomes molten and is continuously
carried with the macro-flow of the weld metal. A through thickness flow of
metal was revealed in the X-rat imaging of the lead tracer in addition to
revealing a cycle oscillation in the plasticized metal affected by the process
[3]. The tensile strength is directly proportional to traverse speed (TS).
Softening of the material was observed in the weld region and mostly evident in
the heat-affected zone (HAZ) on the advancing side of the welds and corresponded
to the failure location in tensile tests. The reason for this phenomenon is due
to the kinetic and thermal asymmetry of the FSW process [4]. The New welding approach has been
introduced to improve the weldeing quality of TIG welded joint, the influence
of friction stir processing on TIG welded joint have been analyzed and they
observed mechanical properties and heat transfer of TIG+FSP welded joint. The
mechanical properties of TIG+FSP welded joint were observed better than TIG
welded joints. [5-11]. The tensile strength of the joint is lower than
that of the base metal. Decrease in hardness in the weld region and tunnel
defect were observed at the intersection of SZ and thermo-mechanically affected
zone (TMAZ) due to high rotational speed and traverse speed. Also, the welded
samples did not fail in bend test [12]. The effect of process parameters on the
joint performance was studied and found that 1600 rpm and 225 mm/min gave 2.8
mm penetration for 3 mm thick workpieces with 4 mm tool root diameter, and the
3 mm tip diameter [13]. The failure occurred at a much lower load during
tensile loading than during shear loading. Also, the authors presented
experimental data on load carrying capacities and fatigue of dissimilar
aluminium-alloy FSW welds [14]. The mechanical property variations in
AA3003-H24 and 2124/Sic/25p–t4 alloy joints at rotational speed of 900 rpm and
traverse speed of 125 mm/min. It was found that the maximum tensile strength is
about 182 MPa. And, the hardness across the weld nugget varies and a minimum
value occurred on retreating side of the HAZ [15]. The rotational speed and
welding feed rate are the factors that have greater influence on hardening parameters
The numerical models response surface hardening models (RSHM) were compared
with those through least square hardening models (LSHM) and confronted to the
experimental results. Indeed, within the limit of a relative average deviation
of about 9.3%, between the experimental model and numerical models expressed in
terms of tension-elongation, the validity of these models is acceptable [16]. The
experiments with and without silicon carbide powder and analyzed the effect of
RS in the range of 600-1200 rpm and TS in the range of 36-72 mm/min. The
optimal values were found at 1200 rpm, 72 mm/min and axial load of 8 kN. Also,
it was found that maximum hardness occurred at the centre of the weld as
compared to other zones of weld joint and is attributed to intensive stirring
process [17]. The joining of dissimilar aluminum-alloys (AA6262-T6 and
AA7075-T6) by varying the weld process parameters (tool rotational speed, weld
speed and axial force) with cylindrical tool-pin profile have been analyzed and
they concluded that better mechanical properties (hardness and tensile
strength) are obtained with the FSW plate welded with 1200 rpm, 36 mm/min and
9kN axial force as compared with other range of values. The main idea of this
research was to study the joining of dissimilar materials AA5083 and AA6082
using the friction stir welding method. The objective of present work is to
optimize the process parameters such as tool rotational speed, traverse speed
and tilt angle for obtaining the greater or optimum value of mechanical
properties like ultimate tensile strength, micro-hardness and residual stress
of the friction stir welded joint of AA6082 and AA5083.
Table
1: Chemical composition of base
material
Al- alloy |
Si |
Fe |
Cu |
Mn |
Mg |
Cr |
Zn |
Ti |
Al |
AA5083 |
0.4 |
0.3 |
0.2 |
0.6 |
4.5 |
0.1 |
0.2 |
0.1 |
Bal |
AA6082 |
1.2 |
0.2 |
0.1 |
0.4 |
0.6 |
0.2 |
0.3 |
0.2 |
Bal |
Run |
A:Tool Rotation Speed (rpm) |
B:Traverse speed (mm/min) |
C:Tilt Angle (º) |
1 |
1150 |
45 |
2 |
2 |
1300 |
30 |
0 |
3 |
1150 |
45 |
0 |
4 |
1000 |
30 |
0 |
5 |
1150 |
45 |
1 |
6 |
1000 |
60 |
2 |
7 |
1300 |
45 |
1 |
8 |
1150 |
45 |
1 |
9 |
1150 |
45 |
1 |
10 |
1300 |
60 |
0 |
11 |
1150 |
45 |
1 |
12 |
1000 |
60 |
0 |
13 |
1150 |
30 |
1 |
14 |
1150 |
45 |
1 |
15 |
1000 |
45 |
1 |
16 |
1300 |
60 |
2 |
17 |
1150 |
60 |
1 |
18 |
1000 |
30 |
2 |
19 |
1150 |
45 |
1 |
20 |
1300 |
30 |
2 |
3.
Results and
discussion
3.1 Tensile strength
At same rotational speed, the tensile
strength decreased with increasing traverse speed. However, the tensile
strength and mean hardness of FSW joint are closer to the base metal values at
1300 rpm and 45 mm/min with tilt angle 1° and therefore considered to be
optimum process parameters. Based on the observed trends, it can be concluded
that there should be a trade-off between tensile strength and hardness while
selecting the optimum process parameters. When the rotational speed increased,
the heat input per unit length of the welded joint also increased which caused
a fine uniform grain refinement was obtained to improve the tensile strength. When
the tool rotational speed increases from 1300 rpm may produce an excessive
release of stirred welded material on the top surfaces of the base plate,
obtained micro void into the stirred zone.
The tensile strength of welded joints was
varied between 161-214 MPa. The minimum tensile strength (161 MPa) was observed
at tool rotation 1000 rpm, traverse speed 30 mm/min with tilt angle 2º, whereas
maximum tensile strength was observed at at tool rotation 1300 rpm, traverse
speed 45 mm/min with tilt angle 1º as shown in fig. 3.
The increase in temperature as well as
coarsening of grains and cooling rate at more than desired temperature may
reduce the tensile strength of the welded joint of at high traverse speed. Some
defects were observed when the material flow around the advancing side (A.S) of
the weldment, because there is no force promoting its movement back into the
volume stirred by the moving tool [18]. All the fracture occurred at the
interface or near the nugget zone (NZ) and thermo mechanically affected zone
(TMAZ) on the advancing side (AS). The reason of fracture near to the nugget
zone and thermo mechanically affect zone may be resulting in many coarse grains
brittle structure near to the NZ and TMAZ [19]. It may be noted that the all
joints are fractured at the advancing side, this shows that the tensile
strength of these weldment are not same on both side to the weld center, it
means the strength of advancing side is weaker than the retreating side (RS).
Run |
A:Tool Rotation Speed (rpm) |
B:Traverse speed (mm/min) |
C:Tilt Angle ( º ) |
Tensile Strength (MPa) |
Strain (%) |
Hardness at Nugget (HV) |
Residual Stress at Nugget (MPa) |
1 |
1150 |
45 |
2 |
163 |
13 |
66 |
38 |
2 |
1300 |
30 |
0 |
194 |
24 |
83 |
24 |
3 |
1150 |
45 |
0 |
182 |
20 |
75 |
25 |
4 |
1000 |
30 |
0 |
175 |
15 |
70 |
33 |
5 |
1150 |
45 |
1 |
195 |
21 |
81 |
14 |
6 |
1000 |
60 |
2 |
154 |
14 |
61 |
44 |
7 |
1300 |
45 |
1 |
214 |
24 |
86 |
12 |
8 |
1150 |
45 |
1 |
192 |
22 |
80 |
15 |
9 |
1150 |
45 |
1 |
190 |
22 |
81 |
18 |
10 |
1300 |
60 |
0 |
177 |
16 |
73 |
29 |
11 |
1150 |
45 |
1 |
189 |
21 |
80 |
20 |
12 |
1000 |
60 |
0 |
167 |
16 |
66 |
36 |
13 |
1150 |
30 |
1 |
181 |
20 |
75 |
26 |
14 |
1150 |
45 |
1 |
187 |
21 |
78 |
21 |
15 |
1000 |
45 |
1 |
188 |
22 |
79 |
23 |
16 |
1300 |
60 |
2 |
174 |
14 |
68 |
35 |
17 |
1150 |
60 |
1 |
178 |
18 |
73 |
27 |
18 |
1000 |
30 |
2 |
161 |
15 |
63 |
40 |
19 |
1150 |
45 |
1 |
188 |
23 |
82 |
28 |
20 |
1300 |
30 |
2 |
187 |
22 |
76 |
22 |
3.2 Micro-hardness
at Nugget zone
Fig. 5 shows the variation between
micro-hardness and processing parameters of the friction stir welded joint of
AA5083 and AA6082. Although the investigation of the microhardness across the
weldment of AA5083 and AA6082 has been reported earlier [20]. The stirred zone
(SZ) of friction stir welding have the highest hardness in the welded zone due
to the high temperature which results in the dissolution of the precipitation
phase in that zone. This increase in the hardness at the stirred zone was
observed in friction stir welding of other precipitation hardened alloys [21].
3.3 Residual stress at Nugget zone
3.4 Evaluating the
adequacy of the developed model
The empirical relationship for the output
responses i.e. tensile strength, micro-hardness and residual stress has been
developed and the adequacy was analyzed by response surface methodology (RSM)
technique. The FSW experiments were designed with the help of design expert
software with 20 experiments. To identify the process parameters that are
statistically significant, analysis of variance (ANOVA) test was conducted. The
purpose of ANOVA test is to determine the significance of process parameters
which affect the mechanical properties of friction stir welded joints. The
F-test (Fisher’s test) may also be used to determine which process parameter
has a significant effect on the mechanical properties. The results of ANOVA
test show that the opt process parameters are highly significant factor
affecting the mechanical properties of friction stir welded joint in order to
tool rotational speed, traverse speed and tilt angle. The developed models were
tested using ANOVA method with the help of design expert software. The ANOVA
results for tensile strength, percentage elongation and hardness at nugget
zones are shown in table 4-6. The all models give the highly significant
fisher’s F value which shows that the model adequately representing the
relationship between process parameters and response. The fisher’s F value of
developed model for tensile strength is 26.67 which shows that the model is
significant and there is only 0.01% chance that a model Fisher’s value could
occur due to noise. The lack of fit F value of 2.28 shows that the lack of fit
is not significant. For a good model lack of fit should be not significant. The
residual error value (150.93) should be the sum of lack of fit (104.96) and
pure error (46). By this column of fit summary recommended quadratic model is
statically significant for analyzing the tensile stress of welded joint of
AA5083 and AA6082. The fisher’s F value of developed model for percentage
elongation is 12.51 which shows that the model is significant and there is only
0.02% chance that a model Fisher’s value could occur due to noise. The lack of
fit F value of 5.18 shows that the lack of fit is not significant. For a good
model lack of fit should be not significant. The residual error value (20.6)
should be the sum of lack of fit (17.27) and pure error (3.33). By this column
of fit summary recommended quadratic model is statically significant for
analyzing the percentage elongation of welded joint of AA5083 and AA6082. The
fisher’s F value of developed model for micro-hardness at nugget zone is 36.13
which shows that the model is significant and there is only 0.01% chance that a
model Fisher’s value could occur due to noise. The lack of fit F value of 2.09
shows that the lack of fit is not significant. For a good model lack of fit
should be not significant. The residual error value (28.8) should be the sum of
lack of fit (19.47) and pure error (9.33). By this column of fit summary
recommended quadratic model is statically significant for analyzing the
micro-hardness at nugget zone of welded joint of AA5083 and AA6082. The
fisher’s F value of developed model for residual stress at nugget zone is 8.34
which shows that the model is significant and there is only 0.13% chance that a
model Fisher’s value could occur due to noise. The lack of fit F value of
0.8298 shows that the lack of fit is not significant. For a good model lack of
fit should be not significant. By this column of fit summary recommended
quadratic model is statically significant for analyzing the residual stress at
nugget zone of welded joint of AA5083 and AA6082.
3.5
Developing a
mathematical model
The empirical relationship was developed
for the response variable i.e. ultimate tensile strength, percentage
elongation, and micro-hardness and residual stress at nugget zone under the
input processing parameters i.e. tool rotational speed (A), traverse speed (B)
and tilt angle (c) using analysis of variance technique with the help of design
expert software. The mathematical empirical relationship for tensile strength,
percentage elongation and micro-hardness at nugget zone are as follow.
Tensile strength =
696.7 – 1.12A + 4.67B + 8.56C
– 0.00083AB + 0.0175 AC + 0.04167 BC + 0.00052A2 – .0452 B2
– 18.18C2
Residual stress = 55.32 +0.28A –2.895B –11.08C + 0.00061AB – 0.00916AC + 0.075BC– 0.000145A2+0.0254B2+10.72C2
Table
4: analysis of variance (ANOVA) test for tensile strength
Tensile Strength |
||||||
Source |
Sum of Squares |
df |
Mean Square |
F-value |
p-value |
|
Model |
3622.27 |
9 |
402.47 |
26.67 |
< 0.0001 |
significant |
A-Tool Rotation Speed |
1000 |
1 |
1000 |
66.25 |
< 0.0001 |
significant |
B-Traverse speed |
230.4 |
1 |
230.4 |
15.26 |
0.0029 |
significant |
C-Tilt Angle |
336.4 |
1 |
336.4 |
22.29 |
0.0008 |
significant |
AB |
28.13 |
1 |
28.13 |
1.86 |
0.2022 |
significant |
AC |
55.13 |
1 |
55.13 |
3.65 |
0.0851 |
significant |
BC |
3.13 |
1 |
3.13 |
0.207 |
0.6588 |
significant |
A² |
384.09 |
1 |
384.09 |
25.45 |
0.0005 |
significant |
B² |
285.09 |
1 |
285.09 |
18.89 |
0.0015 |
significant |
C² |
909.09 |
1 |
909.09 |
60.23 |
< 0.0001 |
significant |
Residual |
150.93 |
10 |
15.09 |
|
|
|
Lack of Fit |
104.93 |
5 |
20.99 |
2.28 |
0.1932 |
not significant |
Pure Error |
46 |
5 |
9.2 |
|
|
|
Cor Total |
3773.2 |
19 |
|
|
|
|
Table 5: analysis of variance (ANOVA) test for percentage
elongation
% Elongation |
||||||
Source |
Sum of Squares |
df |
Mean Square |
F-value |
p-value |
|
Model |
231.95 |
9 |
25.77 |
12.51 |
0.0002 |
significant |
A-Tool Rotation Speed |
32.4 |
1 |
32.4 |
15.73 |
0.0027 |
significant |
B-Traverse speed |
32.4 |
1 |
32.4 |
15.73 |
0.0027 |
significant |
C-Tilt Angle |
16.9 |
1 |
16.9 |
8.2 |
0.0168 |
significant |
AB |
32 |
1 |
32 |
15.53 |
0.0028 |
significant |
AC |
0.5 |
1 |
0.5 |
0.2427 |
0.6329 |
significant |
BC |
0.5 |
1 |
0.5 |
0.2427 |
0.6329 |
significant |
A² |
11 |
1 |
11 |
5.34 |
0.0434 |
significant |
B² |
11 |
1 |
11 |
5.34 |
0.0434 |
significant |
C² |
55.69 |
1 |
55.69 |
27.03 |
0.0004 |
significant |
Residual |
20.6 |
10 |
2.06 |
|
|
|
Lack of Fit |
17.27 |
5 |
3.45 |
5.18 |
0.0476 |
Not significant |
Pure Error |
3.33 |
5 |
0.6667 |
|
|
|
Cor Total |
252.55 |
19 |
|
|
|
|
Micro-Hardness |
||||||
Source |
Sum of Squares |
df |
Mean Square |
F-value |
p-value |
|
Model |
936.4 |
9 |
104.04 |
36.13 |
< 0.0001 |
significant |
A-Tool Rotation Speed |
220.9 |
1 |
220.9 |
76.7 |
< 0.0001 |
significant |
B-Traverse speed |
67.6 |
1 |
67.6 |
23.47 |
0.0007 |
significant |
C-Tilt Angle |
108.9 |
1 |
108.9 |
37.81 |
0.0001 |
significant |
AB |
18 |
1 |
18 |
6.25 |
0.0314 |
significant |
AC |
0 |
1 |
0 |
0 |
1 |
significant |
BC |
2 |
1 |
2 |
0.6944 |
0.4241 |
significant |
A² |
33.69 |
1 |
33.69 |
11.7 |
0.0065 |
significant |
B² |
68.75 |
1 |
68.75 |
23.87 |
0.0006 |
significant |
C² |
198.69 |
1 |
198.69 |
68.99 |
< 0.0001 |
significant |
Residual |
28.8 |
10 |
2.88 |
|||
Lack of Fit |
19.47 |
5 |
3.89 |
2.09 |
0.2195 |
not significant |
Pure Error |
9.33 |
5 |
1.87 |
|||
Cor Total |
965.2 |
19 |
3.6 Influence of
process parameters on tensile strength, micro-hardness and residual stress
When the feed rate or traverses speed increases, the tensile strength and hardness also increases up to a certain value. Large heat was found in the welded region at lower welding traverse speed. As the traverse speed increases, the effect of thermal cycle on the welded joint properties is weakened leading to an improvement in tensile strength and hardness of the welded joint.
When the tool rotational speed is compared
with the tilt angle and traverse speed then the rotational speed is more
sensitive to change or increase the tensile strength and micro-hardness of the
friction stir welded joint of AA5083 and AA6082 because the heat generation is
mainly depended on tool rotational speed, higher tool rotational speed produces
higher heat generation [23]. The cube function graph of multi response
optimization as shown in fig. 10-11. This methodology is used to optimize for
more than one objective function. The desirable value is 1 for optimized value
of the input processing parameters and responses. The optimized value of
tensile strength, percentage elongation, micro-hardness at nugget zone and
residual stress at nugget zone are 187.6 MPa, 19.93, 78.39 HV and 22.02 MPa
respectively, whereas the optimized value of tool rotational speed, feed rate
and tilt angle are 1227.7 rpm, 53.20 mm/min and 0.3741 respectively as shown in
fig. 12.
The present work was design to optimize
the processing parameters of friction stir welded joints of dissimilar aluminum
alloy of AA5083 and AA6082 and the following conclusions have been made.
·
Friction
stir welding of dissimilar aluminum alloys AA5083 and AA6082 aluminum alloys of
6 mm plates have been welded.
·
The
experiments were designed with the help of CCD of RSM and the FSW parameters
such as tool rotational speed, traverse speed and tilt angle were considered.
·
The
maximum tensile strength (214 MPa) was found at tool rotation speed 1300 rpm,
traverse speed 45 mm/min with tilt angle 10
·
The
maximum micro-hardness (86 HV) was found at tool rotation speed 1300 rpm,
traverse speed 45 mm/min with tilt angle 10
·
The
minimum tensile strength (161 MPa) was observed at tool rotation speed 1000
rpm, traverse speed 30 mm/min with tilt angle 20.
·
In
addition, a numerical model and empirical relationship was developed by design
expert software between processing parameters (tool rotation speed, traverse
speed, and tilt angle) and response surface parameters (tensile strength,
percentage elongation and micro-hardness at nugget zone) and the optimized
value of tensile strength, % elongation, micro-hardness, and residual stress
were observed as 187.6 MPa, 19.93, 78.39 HV and 22.02 MPa respectively.
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Cite this article as: Muzamil Farooq,
Amit Gupta, Vikas Nandal, Optimization of process parameters of friction stir
welded joint of dissimilar aluminum alloy AA5083 and AA6082, International
journal of research in engineering and innovation (IJREI), vol 5, issue 1
(2020), 10-19. https://doi.org/10.36037/IJREI.2021.5102. |
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