Modeling and optimization of friction stir welding parameters in joining 5086 H32 aluminium alloy.

Document Type : Article

Authors

1 Department of Mechanical Engineering, Deenbandhu Chhotu Ram University of Science and Technology, Murthal Sonepat, India.

2 Department of Mechanical Engineering Deenbandhu Chhotu Ram University of science and Technology, Murthal-131039 Sonepat, India.

Abstract

The present manuscript focuses on developing a mathematical model to predict the
intergranular corrosion rate of friction stir welded AA5086 H32 aluminium alloy joints. Six
factors-Five levels central composite design matrix, having 52 experiments, is used for design
of experiments. The developed model is used to examine the impact of studied process
parameters i.e. rotational speed, welding speed, tool shoulder diameter, tool hardness, tilt
angle , and pin profile on intergranular corrosion rate of the welded joints. Response surface
methodology is used to optimize the process parameters for minimizing the susceptibility to
intergranular corrosion attack. The optimum combination of studied parameters, to have
minimum corrosion rate i.e. 3.2 mg/cm2, is obtained as 1296 rpm rotational speed, 79.4
mm/min welding speed, 14.9 mm tool shoulder diameter, 47.4 HRC tool hardness, 2.380 tilt
angle, and square pin profile.

Keywords

Main Subjects


1. Thomas, W.M., Nicholas, E.D., Needham, J.C., and Dawes, C.J., International Patent Application No. PCT/GB92/02203 (1991). 2. Dinaharan, I., Murugan, N., and Parameswaran, S. Developing an empirical relationship to predict the inuence of process parameters on tensile strength of friction stir welded AA6061/0-10 wt% ZrB2 in situ composite", Transactions of the Indian Institute of Metals, 65(2), pp. 59-170 (2012). 3. Peddavarapu, S., Raghuraman, S., Bharathi, R.J., Sunil, G.V.S., and Manikanta, D.B.N.S. Micro structural investigation on friction stir welded Al-4.5 Cu- 5TiB2 Composite", Transactions of the Indian Institute of Metals, 70(3), pp. 703-708 (2017). 4. Mehta, K.P. and Badheka, V.J. E_ects of tilt angle on the properties of dissimilar friction stir welding copper to aluminum", Materials and Manufacturing Processes, 31(3), pp. 255-263 (2016). 5. Aval, H.J. Inuences of pin pro_le on the mechanical and microstructural behaviors in dissimilar friction stir welded AA6082-AA7075 butt joint", Materials & Design, 67, pp. 413-421 (2015). 6. Aziz, S.B., Dewan, M.W., Huggett, D.J., Wahab, M.A., Okeil, A.M., and Liao, T.W. Impact of friction stir welding (FSW) process parameters on thermal modeling and heat generation of aluminum alloy joints", Acta Metallurgica Sinica (English Letters), 29(9), pp. 869-883 (2016). 7. Subbaiah, K., Geetha, M., Govindaraju, M., and Rao, S.K. Mechanical properties of friction stir welded cast Al-Mg-Sc alloys", Transactions of the Indian Institute of Metals, 65(2), pp. 155-158 (2012). 8. Yan, Z.J., Liu, X.S., and Fang, H.Y. Fatigue behavior of dissimilar Al-Mg-Si/Al-Zn-Mg aluminum alloys friction stir welding joints", Acta Metallurgica Sinica (English Letters), 29(12), pp. 1161-1168 (2016). A. Goyal and R.K. Garg/Scientia Iranica, Transactions B: Mechanical Engineering 26 (2019) 2407{2417 2417 9. Reddy, G.M., Mastanaiah, P., Prasad, K.S., and Mohandas, T. Microstructure and mechanical property correlations in AA 6061 aluminium alloy friction stir welds", Transactions of the Indian Institute of Metals, 62(1), pp. 49-58 (2009). 10. Behnagh, R.A., Besharati Givi, M.K., and Akbari, M. Mechanical properties, corrosion resistance, and microstructural changes during friction stir processing of 5083 aluminum rolled plates", Materials and Manufacturing Processes, 27(6), pp. 636-640 (2012). 11. Colligan, K.J. Friction stir welding for ship construction", Contract, 14, pp. 1-6 (2004). 12. Taban, E. and Kaluc, E. Comparison between microstructure characteristics and joint performance of 5086-H32 aluminium alloy welded by MIG, TIG and friction stir welding processes", Kovove Materialy, 45(5), pp. 241-248 (2007). 13. Aval, H.J. and Loureiro, A. E_ect of welding parameters on microstructure, mechanical properties and residual stress _elds of friction stir welds on AA5086", Kovove Materialy, 53, pp. 51-58 (2015). 14. Jamalian, H.M., Farahani, M., Givi, M.B., and Vafaei, M.A. Study on the e_ects of friction stir welding process parameters on the microstructure and mechanical properties of 5086-H34 aluminum welded joints", The International Journal of Advanced Manufacturing Technology, 83(1-4), pp. 611-621 (2016). 15. Amini, K. and Gharavi, F. Inuence of welding speed on corrosion behaviour of friction stir welded AA5086 aluminium alloy", Journal of Central South University, 23(6), pp. 1301-1311 (2016). 16. Milkey, K.R., Samsudin, A.R., Dubey, A.K., and Kidd, P. Comparison between taguchi method and response surface methodology (RSM) in modelling CO2 laser machining", Jordan Journal of Mechanical & Industrial Engineering, 8(1), pp. 35-42 (2014). 17. Goyal, A. and Garg, R.K. E_ect of tool rotational and transverse speed on mechanical properties of friction stir welded AA5086-H32 aluminium alloy", International Journal of Microstructure and Materials Properties, 12(1-2), pp. 79-93 (2017). 18. Rajakumar, S., Muralidharan, C., and Balasubramanian, V. Predicting tensile strength, hardness and corrosion rate of friction stir welded AA6061-T 6 aluminium alloy joints", Materials & Design, 32(5), pp. 2878-2890 (2011). 19. Rajakumar, S. and Balasubramanian, V. Predicting grain size and tensile strength of friction stir welded joints of AA7075-T6 aluminium alloy", Materials and Manufacturing Processes, 27(1), pp. 78-83 (2012). 20. Standard test method for determining the susceptibility to intergranular corrosion of 5XXX series aluminum alloys by mass loss after exposure to nitric acid (NAMLT Test)", ASTM International (2004). 21. Bouzid, L., Berkani, S., Yallese, M., Girardin, F., and Mabrouki, T. Estimation and optimization of ank wear and tool lifespan in _nish turning of AISI 304 stainless steel using desirability function approach", International Journal of Industrial Engineering Computations, 9(3), pp. 349-368 (2018).