Optimization of friction stir welding parameters with Taguchi method for maximum electrical conductivity in Al-1080 welded sections

Document Type : Article

Authors

1 Department of Mechanical Engineering, College of Engineering, Tabriz Branch, Islamic Azad University, Tabriz, Iran

2 Department of Mining Engineering, Engineering Faculty, Urmia University, Urmia, P.O. Box 57561/51818, Iran

Abstract

In this paper, an attempt has been made to optimize the welding parameters. FSWed sections strength and quality is affected by materials transfer, work hardening and transformations. These properties depends strongly on the materials transfer, which is under the control of welding parameters. The soundness of friction stir welded sections usually studied by NDT techniques. However, it could be characterized by physical properties such as electrical conductivity. As the higher electrical conductivity, means lower defects and higher welding quality. For this purpose, the Taguchi L9 orthogonal design of experiment was used to optimize the welding parameters. The optimum process parameters and their effectiveness on the electrical conductivity of welded sections were analyzed by S/N ratio and ANOVA tests. The results indicated that the tilt angle and tool shape are the most influential parameters to catch the maximum conductivity in welded joints. The optimum tool shape and tilt angle are cylindrical and 3º. The optimum conditions for welding speed and rotational speed were obtained as following; 100 mm/min and 900 rpm in stir zone, 250 mm/min and 900 rpm in advancing side (AS) and 100 mm/min and 450 rpm in Retreating side (RS), respectively.

Keywords


References
1.            Mishra, R.S. and Z, Ma. "Friction stir welding and processing", Materials science and engineering., 50(1-2), p. 1-78 (2005).
2.            Sato, Y.S. M, Urata. and H, Kokawa. "Parameters controlling microstructure and hardness during friction-stir welding of precipitation-hardenable aluminum alloy 6063", Metallurgical and Materials Transactions A., 33(3), p. 625-635 (2002).
3.            Colligan, K. "Material flow behavior during friction welding of aluminum", Weld J., 75(7), p. 229s-237s (1999).
4.            Malik, V. et al. "Investigations on the effect of various tool pin profiles in friction stir welding using finite element simulations", Procedia Engineering., 97, p. 1060-1068 (2014).
5.            Akinlabi, E. D, Madyira. and S, Akinlabi. "Effect of heat input on the electrical resistivity of dissimilar friction stir welded joints of aluminium and copper", AFRICON IEEE., (2011).
6.            Darras, B. et al. "Friction stir processing of commercial AZ31 magnesium alloy", Journal of materials processing technology., 191(1-3), p. 77-81 (2007).
7.            Avettand enoël, M. et al. "Multiscale study of interfacial intermetallic compounds in a dissimilar Al 6082-T6/Cu friction-stir weld", Metallurgical and Materials Transactions A., 43(12), p. 4655-4666 (2012).
8.            Yang, J. et al. "A probabilistic crack size quantification method using in-situ Lamb wave test and Bayesian updating", Mechanical Systems and Signal Processing., 78, p. 118-133 (2016).
9.            Hou, J. H, Liu. and Y, Zhao. "Influences of rotation speed on microstructures and mechanical properties of 6061-T6 aluminum alloy joints fabricated by self-reacting friction stir welding tool", 73(5-8), p. 1073-1079 (2014).
10.          Delir Nazarlou, R. F, Omidbakhsh. and J, Mollaei Milani. "Effect of rotational speed in friction stir welding on the material transfer mechanism in commercial pure aluminum", Journal of Welding Science and Technology of Iran., 6(1), p. 9-17 (2020).
11.          Anawa, E. and A.G, Olabi. "Using Taguchi method to optimize welding pool of dissimilar laser-welded components", Optics & Laser Technology., 40(2), p. 379-388 (2008).
12.          Chien, C.H. W.B, Lin. and T, Chen "Optimal FSW process parameters for aluminum alloys AA5083" ,Journal of the Chinese Institute of Engineers., 34(1), p. 99-105 (2011).
13.          Ugrasen, G. et al. "Optimization of process parameters for Al6061-Al7075 alloys in friction stir welding using Taguchi’s technique", Materials Today Proceedings., 5(1), p. 3027-3035 (2018).
14.          Sahu, P.K. and S, Pal. "Multi-response optimization of process parameters in friction stir welded AM20 magnesium alloy by Taguchi grey relational analysis", Journal of Magnesium and Alloys., 3(1), p. 36-46 (2015).
15.          Shunmugasundaram, M. et al. "Optimization of process parameters of friction stir welded dissimilar AA6063 and AA5052 aluminum alloys by Taguchi technique", Materials Today Proceedings., (2020).
16.          Panda, M.R. S.S, Mahapatraand. and C.P, Mohanty. "Parametric investigation of friction stir welding on AA6061 using Taguchi technique", Materials Today Proceedings., 2(4-5), p. 2399-2406 (2015).
17.          Goyal, A. and R.K, Garg. "Establishing mathematical relationships to study tensile behavior of friction stir welded AA5086-H32 aluminium alloy joints", Silicon., 11(1), p. 51-65 (2019).
18.          Akhgar, B. et al. "Application of Taguchi method for optimization of synthetic rutile nano powder preparation from ilmenite concentrate", Chemical engineering research and design., 90(2), p. 220-228 (2012).
19.          Keleş, O. "An optimization study on the cementation of silver with copper in nitrate solutions by Taguchi design", Hydrometallurgy., 95(3-4), p. 333-336 (2009).
20.          Akinlabi, E.T. S.A, Akinlabi. and K, Surekha. "Effect of friction stir processing on the electrical resistivity of AA 6082", Africon IEEE., (2013).
21.          Sharma, N. et al. "Effect of process parameters on microstructure and electrical conductivity during FSW of Al-6101 and pure copper", Materials Research Express., 5(4), p. 046519 (2018).
22.          Kahl, S. "Fatigue strength of friction stir welds in aluminium alloy AA6082-T6", TWI Friction Stir Welding Symposium., (2010).
23.          Kafali, H. and N, Ay. "Mechanical properties of 6013-T6 aluminium alloy friction stir welded plate", 13th International Conference Aerospace Sciences & Aviation Technology., (2009).
24.          Wan, L. et al. "Friction stir welding of aluminium hollow extrusion: weld formation and mechanical properties", Materials Science and Technology., 31(12), p. 1433-1442 (2015).
25.          Lee, E. et al. "The effect of thermal exposure on the electrical conductivity and static mechanical behavior of several age hardenable aluminum alloys", Engineering Failure Analysis., 14(8), p. 1538-1549, (2007).
26.          Frigaard, Ø. Ø, Grong. and O, Midling. "A process model for friction stir welding of age hardening aluminum alloys", Metallurgical and materials transactions A., 32(5), p. 1189-1200 (2001).
27.          Gu, J. et al. "The effect of inter-layer cold working and post-deposition heat treatment on porosity in additively manufactured aluminum alloys", Journal of materials processing technology., 230, p. 26-34 (2016).
28.          Silva, M. R, Gouyon. and F, Lepoutre. "Hidden corrosion detection in aircraft aluminum structures using laser ultrasonics and wavelet transform signal analysis", Ultrasonics., 41(4), p. 301-305 (2003).
29.          Liu, H. et al. "Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy", Journal of materials processing technology., 142(3), p. 692-696 (2003).