This document presents an optimization study of friction stir welding process parameters for aluminum alloys to achieve maximum tensile strength. Experiments were conducted using Taguchi's design of experiments method to evaluate the effects of rotational speed, tool tilt angle, and travel speed on joint strength. Analysis of variance revealed that tool tilt angle was the most influential parameter, contributing 47.39% to tensile strength, followed by travel speed at 42.18%. The optimal parameters predicted were 1300 rpm rotational speed, 1° tool tilt angle, and 60 mm/min travel speed, which were expected to yield a maximum tensile strength of 285 MPa. Experimental validation of these optimal parameters produced a joint strength of 288 MPa, close to the predicted value.
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This document summarizes research on optimizing parameters for friction stir welding (FSW) of aluminum alloys. It first provides background on FSW and discusses how parameters like tool rotation speed, tilt angle, and travel speed affect weld strength. The document then reviews several other studies investigating these parameters. One study found that a tool rotation speed of 900 rpm, travel speed of 75 mm/min, and axial force of 3 kN produced the highest tensile strength for an aluminum alloy. Another identified tilt angle as the most influential parameter for weld strength. Finally, the document describes using the Taguchi method to optimize FSW parameters for aluminum alloy, identifying tilt angle as most significant. It concludes that tool rotation speed, travel
Optimization of Process Parameters of Friction Stir Welding for Similar He-30...IRJET Journal
This document discusses optimization of process parameters for friction stir welding of similar HE-30 aluminium alloy. It begins with an abstract that describes the friction stir welding process and the objectives of using Taguchi methods to optimize welding parameters to achieve high tensile strength. It then provides background on friction stir welding, describing how it is a solid-state welding process that uses a rotating tool to plasticize materials without melting. The document discusses how process parameters like rotational speed, travel speed, and tool geometry can affect joint quality and properties. It aims to use an experimental design and analysis approach to determine the optimum welding conditions for high tensile strength when joining HE-30 aluminium alloy.
Investigation of Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Investigation and analysis of metallurgical and mechanical properties of aa11...Alexander Decker
1. The document investigates the mechanical and metallurgical properties of friction stir welded joints of AA1100 aluminum alloy fabricated at different tool rotational speeds and material positions.
2. Tensile tests, microhardness tests, and optical/SEM microscopy of the welds were used to evaluate the mechanical properties and microstructure of the joints.
3. The results showed that joints welded at 1200 rpm had the optimum properties, with smooth weld surfaces and good tensile strength, yield strength, and elongation. Microhardness was also highest at this welding condition.
FSW PROCESS DISSIMILAR (Al) AT 3G POSITIONMin Dzulkiflee
This document summarizes a research project on friction stir welding (FSW) of dissimilar aluminum alloys. The objectives were to design an FSW weld for joining different aluminum series in a 3G position, evaluate the best welding parameters such as rotational and transverse speed, and analyze tensile strength properties. FSW was performed using different transverse speeds and a fixed rotational speed. Tensile testing showed the highest strength was achieved with a transverse speed of 86mm/min, meeting the project's objectives.
PAPER ON WELDABILITY OF H30 ALUMINIUM WITH BS970 MILD STEEL USING FRICTION WE...Journal For Research
Friction welding method is one of the most simple, economical and highly productive method in joining dissimilar materials. It is widely used in the automotive, medical and aerospace industrial applications. The purpose of this present work was to assess the development of solid state juncture of dissimilar materials of H30 aluminum and BS970 mild steel. The joints were obtained by Friction Welding (FW) process, which combines the heat generated from friction between two surfaces. The results were analyzed by means of tensile, Rockwell hardness test and metallographic tests. Solid state welding processes are characterized by the absence of melting and the formation of narrow heat affected zone (HAZ). The metallurgical properties are usually excellent and most of the processes can be mechanized or automated to be used as high production rate processes. The FW proves to be a great method for obtaining junctures between dissimilar materials which is not possible by fusion welding process.
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. Friction Stir Welding(FSW) process is an emerging solid state joining process in which
the material that is being welded does not melt and recast when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
Friction stir welding of aluminium 5086 alloyseSAT Journals
Abstract Friction Stir welding (FSW) is a solid state attachment method used for welding of metals of same and different metals. This process of friction stir welding (FSW) is widely using for the reason it can produces sound welds and doesn't have common issues like solidification and liquefaction cracking connected to the fusion techniques. The Friction stir welding of Al 5086 alloys had been commercialized and up to date interest is targeted on change of integrity with different metals. Thus on commercialize this method, analysis studies are required to characterize. particularly, FSW has impressed researchers to aim modification of integrity different metals like aluminum 5086 that differ in properties and sound welds with none or restricted inter metallic bonding of components has been done. In this paper we have to make a research on the current analysis state of FSW between aluminum 5086 with attention on the resulting welding and tensile strength, microstructure, elongation and the tools are used to produce the welds and also an insight into future analysis during this process of study the project of friction welding. By this process in our project we got an idea of going to maintain the rotational speed (rpm) 450 to 1400 and also by changing welding rpm (speed). This friction stir welding is used in nasa for joining of two totally different or same types of materials. Keywords: Friction stir welding, Tool, Welding parameters, and Mechanical properties etc…
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This document summarizes research on optimizing parameters for friction stir welding (FSW) of aluminum alloys. It first provides background on FSW and discusses how parameters like tool rotation speed, tilt angle, and travel speed affect weld strength. The document then reviews several other studies investigating these parameters. One study found that a tool rotation speed of 900 rpm, travel speed of 75 mm/min, and axial force of 3 kN produced the highest tensile strength for an aluminum alloy. Another identified tilt angle as the most influential parameter for weld strength. Finally, the document describes using the Taguchi method to optimize FSW parameters for aluminum alloy, identifying tilt angle as most significant. It concludes that tool rotation speed, travel
Optimization of Process Parameters of Friction Stir Welding for Similar He-30...IRJET Journal
This document discusses optimization of process parameters for friction stir welding of similar HE-30 aluminium alloy. It begins with an abstract that describes the friction stir welding process and the objectives of using Taguchi methods to optimize welding parameters to achieve high tensile strength. It then provides background on friction stir welding, describing how it is a solid-state welding process that uses a rotating tool to plasticize materials without melting. The document discusses how process parameters like rotational speed, travel speed, and tool geometry can affect joint quality and properties. It aims to use an experimental design and analysis approach to determine the optimum welding conditions for high tensile strength when joining HE-30 aluminium alloy.
Investigation of Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Investigation and analysis of metallurgical and mechanical properties of aa11...Alexander Decker
1. The document investigates the mechanical and metallurgical properties of friction stir welded joints of AA1100 aluminum alloy fabricated at different tool rotational speeds and material positions.
2. Tensile tests, microhardness tests, and optical/SEM microscopy of the welds were used to evaluate the mechanical properties and microstructure of the joints.
3. The results showed that joints welded at 1200 rpm had the optimum properties, with smooth weld surfaces and good tensile strength, yield strength, and elongation. Microhardness was also highest at this welding condition.
FSW PROCESS DISSIMILAR (Al) AT 3G POSITIONMin Dzulkiflee
This document summarizes a research project on friction stir welding (FSW) of dissimilar aluminum alloys. The objectives were to design an FSW weld for joining different aluminum series in a 3G position, evaluate the best welding parameters such as rotational and transverse speed, and analyze tensile strength properties. FSW was performed using different transverse speeds and a fixed rotational speed. Tensile testing showed the highest strength was achieved with a transverse speed of 86mm/min, meeting the project's objectives.
PAPER ON WELDABILITY OF H30 ALUMINIUM WITH BS970 MILD STEEL USING FRICTION WE...Journal For Research
Friction welding method is one of the most simple, economical and highly productive method in joining dissimilar materials. It is widely used in the automotive, medical and aerospace industrial applications. The purpose of this present work was to assess the development of solid state juncture of dissimilar materials of H30 aluminum and BS970 mild steel. The joints were obtained by Friction Welding (FW) process, which combines the heat generated from friction between two surfaces. The results were analyzed by means of tensile, Rockwell hardness test and metallographic tests. Solid state welding processes are characterized by the absence of melting and the formation of narrow heat affected zone (HAZ). The metallurgical properties are usually excellent and most of the processes can be mechanized or automated to be used as high production rate processes. The FW proves to be a great method for obtaining junctures between dissimilar materials which is not possible by fusion welding process.
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. Friction Stir Welding(FSW) process is an emerging solid state joining process in which
the material that is being welded does not melt and recast when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
Friction stir welding of aluminium 5086 alloyseSAT Journals
Abstract Friction Stir welding (FSW) is a solid state attachment method used for welding of metals of same and different metals. This process of friction stir welding (FSW) is widely using for the reason it can produces sound welds and doesn't have common issues like solidification and liquefaction cracking connected to the fusion techniques. The Friction stir welding of Al 5086 alloys had been commercialized and up to date interest is targeted on change of integrity with different metals. Thus on commercialize this method, analysis studies are required to characterize. particularly, FSW has impressed researchers to aim modification of integrity different metals like aluminum 5086 that differ in properties and sound welds with none or restricted inter metallic bonding of components has been done. In this paper we have to make a research on the current analysis state of FSW between aluminum 5086 with attention on the resulting welding and tensile strength, microstructure, elongation and the tools are used to produce the welds and also an insight into future analysis during this process of study the project of friction welding. By this process in our project we got an idea of going to maintain the rotational speed (rpm) 450 to 1400 and also by changing welding rpm (speed). This friction stir welding is used in nasa for joining of two totally different or same types of materials. Keywords: Friction stir welding, Tool, Welding parameters, and Mechanical properties etc…
INVESTIGATION ON FRICTION STIR WELDING OF SIMILAR ALUMINIUM ALLOYS (AA6061) ...RenukaReddyVudumula
Friction Stir Welding (FSW) is the latest innovative and most complex process that is widely applied to the welding of lightweight alloys, such as aluminum alloys. this process provides the frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the work-pieces. The welding tool is positioned vertically on the material and then moved at welding speed along the joint line.
The plasticized material is transferred behind the tool, forming a welded joint.
In this research, a new approach for friction-stir welding of similar alloys of aluminum alloy 6061 and using cerium particles. The weld mechanical properties of the welds were investigated in this research. The effects of friction-stir welding process parameters such as tool rotational and traverse speeds were also examined. Mechanical properties of the welded parts will be examined by using tensile test, Impact test, and Hardness test.
Optimization of friction stir welding parameters for joining aluminum alloy 6...eSAT Journals
Abstract This investigation represents the effects of parameters of friction stir welding on tensile strength and hardness during welding of Aluminium Alloy 6105. A fabricated FSWM set up was used for welding. A high carbon steel tool having 18 mm shoulder diameter and 5.5 mm pin diameter has been used. It was noted that for the friction stir welding of aluminium alloy 6105, maximum tensile strength is 0.0912 KN/mm2, which is obtain at 1250 rpm tool rotation speed, 25 mm/min welding speed and 00 tilt angle. It was also noted that the maximum vicker hardness is 65.7 which is obtain at 1550 rpm rotational speed, 35 mm/min welding speed and 0.50 tilt angle. Keywords: Friction stir welding, Aluminium alloy 6105, tensile strength, hardness, Taguchi L9 orthogonal array
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
The document summarizes an experimental analysis of weld strength in friction stir welding of different grades of aluminum alloy using different tool geometries. Specifically, it analyzes welding 6061, 7005, and 8011 aluminum alloys with a cylindrical tool and tapered threaded tool. Tensile testing found that the tapered threaded tool produced stronger welds across all aluminum grades compared to the cylindrical tool, with strengths increasing up to 30%. This is because the threaded tool generates more friction and distributes the metal more evenly in the weld zone. Visual analysis also found the threaded tool produced better surface finish quality than the cylindrical tool.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
Effect of welding parameters and tool shape on properties of friction stir we...IJERA Editor
Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. It has many benefits when applied to welding of aluminum alloys. FSW process parameters such as welding speed, rotational speed and tool geometry play vital roles in the weld quality. The aim of this research is to investigate the effects of different welding speeds, rotational speeds and tool pin profile on the weld quality of a AA6061 aluminum alloy. A friction stir welding tool consists of rotating shoulder and pin that heats the working piece by friction and moves a softened alloy around it to form a joint. In this research work the effect of the tool shape and welding parameters (rotating speed and welding speed) on the mechanical properties of an aluminium plates will be investigated experimentally. The induced heat during the welding process played the main role in the mechanical and appearance of the joints, which is related to the welding parameters.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
Review Paper on Friction Stir Welding and its Impact on EnvironmentIRJET Journal
This document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. FSW involves plunging a rotating tool with a shoulder and pin into aluminum or other metal workpieces to generate frictional heat and plasticize the metals, joining them below their melting points. Key benefits of FSW include high weld quality, low distortion, no shielding gas or filler wire needed, and it is more environmentally friendly than arc welding. Process parameters like tool geometry, rotation speed, and pressure influence the weld microstructure and properties. FSW has applications in industries like aerospace, automotive, and shipbuilding.
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
This document summarizes research on the effect of process parameters on the tensile strength of friction stir welded aluminum alloys. It discusses how friction stir welding is a solid-state joining technique used in aerospace, automotive, and other industries. Process parameters like tool rotation speed, traverse speed, and axial force influence weld quality and tensile strength. Several studies investigated how adjusting these parameters affected strength of the welded joints. The optimum parameters were found to produce joints with tensile strengths close to the base metal. Overall, it was concluded that process parameters have a significant impact on weld strength and need to be optimized to achieve the highest possible strength.
Characterization and processing of friction stir welding on copper weldseSAT Journals
This document summarizes research on friction stir welding of copper. It discusses how copper, aluminum, and stainless steel plates were welded using friction stir welding with varying tool profiles, rotational speeds, and welding speeds. Microstructure analysis found intermixing of the metals in the welded regions. Copper to copper and aluminum to aluminum welds were of the highest quality, while stainless steel could not be welded to copper or aluminum due to differences in hardness. The best welding results occurred with a tapered tool, rotational speed of 1120 RPM, and welding speed of 20 mm/min.
FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEWIAEME Publication
This welding is a novel process used to join metallic alloys. Friction stir welding is in vogue in aerospace, automotive and other industrial establishments for connecting alloys like aluminum, magnesium and copper. Rotational speed, welding speed and the angle of attack are important in the process of FSW. They analyze the weld quality. FSW produces stronger weld joint then the original material in selected parameters. FSW is a solid-state process, where metal is not melted uses a cylindrical shouldered tool with a profiled pin rotated and gradually plunged into the weld joint between two metal parts of plate or sheet that are to be welded together.
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
Effect of various process parameters on friction stir welded jointeSAT Journals
Abstract Pure and ZnS added ADP (ammonium dihydrogen phosphate) single crystals have been grown at room temperature by the free evaporation method. A total of six crystals have been grown and characterized structurally, chemically, thermally, optically, mechanically and electrically by using the suitable standard methods. Results obtained indicate that the impurity molecules have entered into the ADP crystal matrix. ZnS addition is found to increase the SHG efficiency significantly. All the grown crystals exhibit good optical transmission in the entire visible region. Results of AC and DC electrical measurements indicate a normal dielectric behaviour for all the six crystals grown. The electrical parameters, viz., DC electrical conductivity, dielectric constant, dielectric loss factor and AC electrical conductivity are found to increase with the increase in temperature. The optical, mechanical and electrical parameters are found to vary nonlinearly with the impurity (ZnS) concentration. Keywords: ADP crystal, Crystal growth, Doped crystals, Physical properties, X-ray diffraction.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Review paper on friction stir welding of various materialIRJET Journal
The document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. It discusses how FSW works, common materials welded, key process parameters like rotational speed and welding speed, and their effects on weld strength and microstructure. Several case studies are presented that examined how varying process parameters impacted tensile strength when welding materials like aluminum alloys, steel, and polymers. The conclusion states that FSW is well-suited for welding aluminum alloys and efforts are ongoing to weld higher-temperature materials and dissimilar metals using this technique.
Friction stir welding enhancing or improving strategies Jayesh Gupta
The document discusses strategies to enhance friction stir welding of aluminum alloys. It describes how tool rotation direction, welding medium, and reinforcement with nanomaterials can improve joint quality and properties. Specifically, it notes that counterclockwise tool rotation and submerged welding in water reduce weld defects compared to clockwise rotation and air welding. It also explains how reinforcing with silicon carbide nanoparticles increases strength, hardness, and wear resistance by restricting grain growth and reducing size through the pinning effect.
This document summarizes an article from the International Journal of Mechanical Engineering and Technology. The article investigates the friction welding parameters for joining copper alloy Cu Zn30. It aims to optimize the parameters of rotational speed, friction pressure, friction time, and forge pressure to achieve maximum tensile strength of the joint. Taguchi methods are used to design the experiment. The results found that friction time had the greatest influence on tensile strength, while for friction pressure and forge pressure also significantly impacted strength. Under optimal parameters of 1500 RPM, 5 seconds, 10 bar, and 20 bar, the joint achieved a tensile strength of 332.92 N/mm2. Regression and statistical analysis supported the parameter optimization results. Microstructure
IRJET- Review Paper on of Single Point Cutting Tool with Taguchi Robust ApproachIRJET Journal
This document presents a review paper on simulating a single point cutting tool process using the Taguchi robust design approach. It discusses using finite element modeling (FEM) software to numerically simulate the turning process and analyze three input factors (depth of cut, cutting speed, and rack angle) and two responses (stress and strain). The Taguchi design of experiments technique is used to develop relationships between factors and responses. Regression modeling is then used to develop equations relating the input parameters to output results. Previous research on measuring cutting temperatures, forces, and modeling metal cutting processes is also reviewed to provide context and validate the current study's approach.
Review on TIG Welding Ang And A-TIG Welding on Aluminum AlloysIRJET Journal
This document summarizes a research paper that studied TIG welding and A-TIG welding of AA5456 aluminum alloys. It investigated the effect of welding parameters on microstructure and mechanical properties. Key findings include:
1) TIG welding with optimized parameters (peak current 80A, base current 40A, speed 230mm/min, frequency 4Hz) produced fine equiaxed grain structure and improved mechanical properties compared to other conditions.
2) A-TIG welding achieved significantly higher weld penetration than conventional TIG welding.
3) Mechanical properties improved by 10-15% after applying post-weld planishing to relieve internal stresses in the weld.
4)
This document describes the design and development of an embedded-based facial recognition system using UDOO Android. The system uses low-cost hardware consisting of a UDOO quad board with an OV5640 camera module and 7-inch touchscreen. Android KitKat 4.4.2 is used as the operating system. Facial recognition is implemented using the OpenCV library and Local Binary Pattern Histogram algorithm to identify and verify individuals from digital images with low implementation and maintenance costs. The system was tested and implemented successfully in laboratories.
This document summarizes a research paper on developing a multi-account embedded ATM card with enhanced security. Key points include:
1) The proposed system would embed multiple bank accounts onto a single smart ATM card, allowing customers to access all accounts from any ATM without carrying multiple cards.
2) Security would be enhanced through fingerprint authentication instead of just a PIN. A fingerprint scanner would be integrated into the ATM to verify customers' identities.
3) This would provide more convenience for customers while reducing fraud risks compared to traditional single-account cards authenticated solely with PINs.
INVESTIGATION ON FRICTION STIR WELDING OF SIMILAR ALUMINIUM ALLOYS (AA6061) ...RenukaReddyVudumula
Friction Stir Welding (FSW) is the latest innovative and most complex process that is widely applied to the welding of lightweight alloys, such as aluminum alloys. this process provides the frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the work-pieces. The welding tool is positioned vertically on the material and then moved at welding speed along the joint line.
The plasticized material is transferred behind the tool, forming a welded joint.
In this research, a new approach for friction-stir welding of similar alloys of aluminum alloy 6061 and using cerium particles. The weld mechanical properties of the welds were investigated in this research. The effects of friction-stir welding process parameters such as tool rotational and traverse speeds were also examined. Mechanical properties of the welded parts will be examined by using tensile test, Impact test, and Hardness test.
Optimization of friction stir welding parameters for joining aluminum alloy 6...eSAT Journals
Abstract This investigation represents the effects of parameters of friction stir welding on tensile strength and hardness during welding of Aluminium Alloy 6105. A fabricated FSWM set up was used for welding. A high carbon steel tool having 18 mm shoulder diameter and 5.5 mm pin diameter has been used. It was noted that for the friction stir welding of aluminium alloy 6105, maximum tensile strength is 0.0912 KN/mm2, which is obtain at 1250 rpm tool rotation speed, 25 mm/min welding speed and 00 tilt angle. It was also noted that the maximum vicker hardness is 65.7 which is obtain at 1550 rpm rotational speed, 35 mm/min welding speed and 0.50 tilt angle. Keywords: Friction stir welding, Aluminium alloy 6105, tensile strength, hardness, Taguchi L9 orthogonal array
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
The document summarizes an experimental analysis of weld strength in friction stir welding of different grades of aluminum alloy using different tool geometries. Specifically, it analyzes welding 6061, 7005, and 8011 aluminum alloys with a cylindrical tool and tapered threaded tool. Tensile testing found that the tapered threaded tool produced stronger welds across all aluminum grades compared to the cylindrical tool, with strengths increasing up to 30%. This is because the threaded tool generates more friction and distributes the metal more evenly in the weld zone. Visual analysis also found the threaded tool produced better surface finish quality than the cylindrical tool.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
Effect of welding parameters and tool shape on properties of friction stir we...IJERA Editor
Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. It has many benefits when applied to welding of aluminum alloys. FSW process parameters such as welding speed, rotational speed and tool geometry play vital roles in the weld quality. The aim of this research is to investigate the effects of different welding speeds, rotational speeds and tool pin profile on the weld quality of a AA6061 aluminum alloy. A friction stir welding tool consists of rotating shoulder and pin that heats the working piece by friction and moves a softened alloy around it to form a joint. In this research work the effect of the tool shape and welding parameters (rotating speed and welding speed) on the mechanical properties of an aluminium plates will be investigated experimentally. The induced heat during the welding process played the main role in the mechanical and appearance of the joints, which is related to the welding parameters.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
Review Paper on Friction Stir Welding and its Impact on EnvironmentIRJET Journal
This document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. FSW involves plunging a rotating tool with a shoulder and pin into aluminum or other metal workpieces to generate frictional heat and plasticize the metals, joining them below their melting points. Key benefits of FSW include high weld quality, low distortion, no shielding gas or filler wire needed, and it is more environmentally friendly than arc welding. Process parameters like tool geometry, rotation speed, and pressure influence the weld microstructure and properties. FSW has applications in industries like aerospace, automotive, and shipbuilding.
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
This document summarizes research on the effect of process parameters on the tensile strength of friction stir welded aluminum alloys. It discusses how friction stir welding is a solid-state joining technique used in aerospace, automotive, and other industries. Process parameters like tool rotation speed, traverse speed, and axial force influence weld quality and tensile strength. Several studies investigated how adjusting these parameters affected strength of the welded joints. The optimum parameters were found to produce joints with tensile strengths close to the base metal. Overall, it was concluded that process parameters have a significant impact on weld strength and need to be optimized to achieve the highest possible strength.
Characterization and processing of friction stir welding on copper weldseSAT Journals
This document summarizes research on friction stir welding of copper. It discusses how copper, aluminum, and stainless steel plates were welded using friction stir welding with varying tool profiles, rotational speeds, and welding speeds. Microstructure analysis found intermixing of the metals in the welded regions. Copper to copper and aluminum to aluminum welds were of the highest quality, while stainless steel could not be welded to copper or aluminum due to differences in hardness. The best welding results occurred with a tapered tool, rotational speed of 1120 RPM, and welding speed of 20 mm/min.
FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEWIAEME Publication
This welding is a novel process used to join metallic alloys. Friction stir welding is in vogue in aerospace, automotive and other industrial establishments for connecting alloys like aluminum, magnesium and copper. Rotational speed, welding speed and the angle of attack are important in the process of FSW. They analyze the weld quality. FSW produces stronger weld joint then the original material in selected parameters. FSW is a solid-state process, where metal is not melted uses a cylindrical shouldered tool with a profiled pin rotated and gradually plunged into the weld joint between two metal parts of plate or sheet that are to be welded together.
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
Effect of various process parameters on friction stir welded jointeSAT Journals
Abstract Pure and ZnS added ADP (ammonium dihydrogen phosphate) single crystals have been grown at room temperature by the free evaporation method. A total of six crystals have been grown and characterized structurally, chemically, thermally, optically, mechanically and electrically by using the suitable standard methods. Results obtained indicate that the impurity molecules have entered into the ADP crystal matrix. ZnS addition is found to increase the SHG efficiency significantly. All the grown crystals exhibit good optical transmission in the entire visible region. Results of AC and DC electrical measurements indicate a normal dielectric behaviour for all the six crystals grown. The electrical parameters, viz., DC electrical conductivity, dielectric constant, dielectric loss factor and AC electrical conductivity are found to increase with the increase in temperature. The optical, mechanical and electrical parameters are found to vary nonlinearly with the impurity (ZnS) concentration. Keywords: ADP crystal, Crystal growth, Doped crystals, Physical properties, X-ray diffraction.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Review paper on friction stir welding of various materialIRJET Journal
The document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. It discusses how FSW works, common materials welded, key process parameters like rotational speed and welding speed, and their effects on weld strength and microstructure. Several case studies are presented that examined how varying process parameters impacted tensile strength when welding materials like aluminum alloys, steel, and polymers. The conclusion states that FSW is well-suited for welding aluminum alloys and efforts are ongoing to weld higher-temperature materials and dissimilar metals using this technique.
Friction stir welding enhancing or improving strategies Jayesh Gupta
The document discusses strategies to enhance friction stir welding of aluminum alloys. It describes how tool rotation direction, welding medium, and reinforcement with nanomaterials can improve joint quality and properties. Specifically, it notes that counterclockwise tool rotation and submerged welding in water reduce weld defects compared to clockwise rotation and air welding. It also explains how reinforcing with silicon carbide nanoparticles increases strength, hardness, and wear resistance by restricting grain growth and reducing size through the pinning effect.
This document summarizes an article from the International Journal of Mechanical Engineering and Technology. The article investigates the friction welding parameters for joining copper alloy Cu Zn30. It aims to optimize the parameters of rotational speed, friction pressure, friction time, and forge pressure to achieve maximum tensile strength of the joint. Taguchi methods are used to design the experiment. The results found that friction time had the greatest influence on tensile strength, while for friction pressure and forge pressure also significantly impacted strength. Under optimal parameters of 1500 RPM, 5 seconds, 10 bar, and 20 bar, the joint achieved a tensile strength of 332.92 N/mm2. Regression and statistical analysis supported the parameter optimization results. Microstructure
IRJET- Review Paper on of Single Point Cutting Tool with Taguchi Robust ApproachIRJET Journal
This document presents a review paper on simulating a single point cutting tool process using the Taguchi robust design approach. It discusses using finite element modeling (FEM) software to numerically simulate the turning process and analyze three input factors (depth of cut, cutting speed, and rack angle) and two responses (stress and strain). The Taguchi design of experiments technique is used to develop relationships between factors and responses. Regression modeling is then used to develop equations relating the input parameters to output results. Previous research on measuring cutting temperatures, forces, and modeling metal cutting processes is also reviewed to provide context and validate the current study's approach.
Review on TIG Welding Ang And A-TIG Welding on Aluminum AlloysIRJET Journal
This document summarizes a research paper that studied TIG welding and A-TIG welding of AA5456 aluminum alloys. It investigated the effect of welding parameters on microstructure and mechanical properties. Key findings include:
1) TIG welding with optimized parameters (peak current 80A, base current 40A, speed 230mm/min, frequency 4Hz) produced fine equiaxed grain structure and improved mechanical properties compared to other conditions.
2) A-TIG welding achieved significantly higher weld penetration than conventional TIG welding.
3) Mechanical properties improved by 10-15% after applying post-weld planishing to relieve internal stresses in the weld.
4)
This document describes the design and development of an embedded-based facial recognition system using UDOO Android. The system uses low-cost hardware consisting of a UDOO quad board with an OV5640 camera module and 7-inch touchscreen. Android KitKat 4.4.2 is used as the operating system. Facial recognition is implemented using the OpenCV library and Local Binary Pattern Histogram algorithm to identify and verify individuals from digital images with low implementation and maintenance costs. The system was tested and implemented successfully in laboratories.
This document summarizes a research paper on developing a multi-account embedded ATM card with enhanced security. Key points include:
1) The proposed system would embed multiple bank accounts onto a single smart ATM card, allowing customers to access all accounts from any ATM without carrying multiple cards.
2) Security would be enhanced through fingerprint authentication instead of just a PIN. A fingerprint scanner would be integrated into the ATM to verify customers' identities.
3) This would provide more convenience for customers while reducing fraud risks compared to traditional single-account cards authenticated solely with PINs.
This document summarizes a research paper that proposes an algorithm to predict epileptic seizures up to 5 minutes in advance using EEG data. The algorithm analyzes EEG recordings to extract seizure prediction characteristics and correlates these with seizure occurrence times. The algorithm could enable preventative therapies by triggering deep brain stimulation to avoid imminent seizures. When tested on 21 patients, the algorithm achieved 81.7% accuracy in predicting seizures up to 5 minutes beforehand, ranging from 80.7-81.5% accuracy for individual brain channels. If validated, this type of advanced seizure prediction could help minimize injuries from sudden seizures.
This document presents a mathematical model of ball bearing anomalies in induction machines. It begins with background on ball bearing failures accounting for around 50% of induction machine breakdowns. It then discusses modeling the kinematic frequencies of ball bearings and developing models to represent anomalies on the outer ring and inner ring. The outer ring anomaly is modeled as a series of radial pulses with a frequency equal to the ball rotation frequency around the outer ring. The inner ring anomaly is modeled in a reference frame rotating with the inner ring speed. The modeling aims to analyze the effects of anomalies on electrical and mechanical quantities of the machine and its stability during operation.
1) The document studies blast wave parameters over the facade of high-rise buildings using the US Army Technical Manual 5-1300. It analyzes incident and reflected pressures, arrival time, and positive phase time duration over a 13-story reinforced concrete building for different TNT charge weights (1000kg and 4000kg) and distances (10m and 40m).
2) Graphs show that for lower charge weights and distances, pressure variation is less over upper floors but more over lower floors. For high charge weights and shorter distances, pressure variation is more uniform but magnitude depends on charge weight and distance.
3) For longer distances, pressure is nearly uniform regardless of charge weight because distance is the predominant factor over angle
This document discusses improvements made to increase the life of dolomite crushing hammers. The existing process involved rolling the head and shank portions separately. The suggested improvements involved forging both the head and shank portions as well as using a circulating water system for quenching instead of a static system. These changes increased the average hammer life from 28.45 hours to 40.01 hours, representing a 27% increase. The increased life reduces operating costs by saving on replacement hammers and downtime for changing hammers. The uniformity of properties from forging both portions and improved quenching contributed to the extended hammer life.
This document discusses the role of operational system design in data warehouse implementation. It begins by introducing the National Rural Health Mission (NRHM) project in India, which aims to provide quality healthcare. The document then discusses operational system and data warehouse design techniques. It notes that data warehouse design relies on input from the organization's operational system. Limitations in the operational system can hinder effective data warehouse implementation. The document analyzes the NRHM operational system and identifies some limitations. It proposes design techniques and practices to address limitations and achieve an effective data warehouse solution to support strategic decision making for the NRHM project.
Comparative Effect of Daily Administration of Allium sativum and Allium cepa ...IOSR Journals
This document summarizes a study that compared the effects of daily administration of garlic and onion extracts on alloxan-induced diabetic rats. Diabetes was induced in female rats by injecting alloxan monohydrate. The diabetic rats were divided into groups that received either garlic extract, onion extract, or saline by oral administration for six weeks. Blood samples were then analyzed for glucose and other biomarkers. The results showed that both garlic and onion extracts significantly reduced serum glucose levels compared to the untreated diabetic rats, with the garlic extract proving more potent. No significant differences were found between the extracts in terms of protecting the kidneys and liver.
This document discusses improving power quality in a grid-integrated photovoltaic (PV) system. A PV system is connected to a grid-interfacing inverter along with both linear and non-linear loads. Hysteresis current control is used to generate switching pulses for the inverter to regulate power flow. Simulation results show that without inverter control, grid current is distorted and total harmonic distortion is high. With the proposed inverter control, current harmonics are reduced, reactive power demand is compensated, and total harmonic distortion is lowered from 17.03% to 5.43%. Therefore, the control approach improves power quality without additional hardware.
This document discusses a practical investigation of the environmental hazards of idle time and speed of a compression ignition engine fueled with Iraqi diesel fuel. The study measured emissions of unburnt hydrocarbon, CO, CO2, NOx, particulate matter, and noise from the engine at various idle speeds (900, 1000, 1200, 1500 rpm) over a 20 minute period. The results showed that increasing idle time increased CO, HC, NOx, PM, and noise emissions, while decreasing CO2 concentrations. Increasing idle speed improved combustion and reduced CO, HC, PM, and noise emissions, while increasing CO2 and NOx emissions. The study concluded that operating the engine at idle for long periods can deteriorate combustion and increase harmful
This document provides an overview of computational cardiac electrophysiology. It discusses the blood flow physiology in the heart and the electrical excitation and conduction system. It describes the cardiac action potential and the specialized conductive tissues that control heart rhythm. It also reviews several common mathematical models used to study cardiac electrophysiology, including cable models, Hodgkin-Huxley models of the action potential, and bidomain and monodomain models. The models aim to provide diagnostic information about heart function and electrical abnormalities by simulating the propagation of electrical signals throughout the heart.
The document presents an optimized fuzzy routing technique for mobile ad hoc networks (MANETs). The goal is to propose a fuzzy routing approach that considers bandwidth, packet success rate, and energy to make routing decisions. All possible source-destination paths are obtained using a disjoint multipath approach and stored in the source node's cache. Route request (RREQ) messages are modified to include bandwidth, packet success rate, and energy values from traversed nodes. The source node then defuzzifies these values and selects the best path. Simulation results show the proposed fuzzy technique achieves better packet delivery ratio and throughput than conventional ad hoc routing like AODV, especially under high load.
The document describes a hybrid computational intelligence method for clustering sense-tagged Nepali documents. The method uses a combination of self-organizing map (SOM), particle swarm optimization (PSO), and k-means clustering. Documents are first represented as vectors using senses from WordNet rather than bag-of-words to address polysemy and synonymy issues. A hybrid SOM+PSO+k-means algorithm is then applied, where SOM is used to generate prototype vectors, PSO finds initial centroids, and k-means performs the final clustering of the prototypes into groups. The method is tested on sense-tagged Nepali text documents.
This document discusses the design, simulation, and analysis of a PWM-based buck converter for low power applications. It begins with an introduction to linear regulators and switching regulators, explaining that switching regulators have higher efficiency. It then provides details on the components and operation of a basic buck converter circuit. The document describes open loop and closed loop buck converter designs, continuous and discontinuous operating modes, and simulations of a buck converter in MATLAB to maintain a constant output voltage of 7.995V with less than 4% ripple. It analyzes the performance of the converter using a PID controller to regulate the output based on variations in load and input voltage.
This document proposes a new dual threshold median filter called Dual Threshold Median Filter (DTMF) for removing random valued impulse noise from digital images while preserving edges. The algorithm has two main stages: noise detection and noise removal. In the detection stage, the maximum and minimum pixel values in a 3x3 window are used to classify the central pixel as noisy or noise-free. Noisy pixels are then replaced in the removal stage using median filtering. The proposed filter is tested on standard images like Lena and Mandrill corrupted with 3-99% random valued impulse noise. Results show it achieves better peak signal-to-noise ratios and lower mean squared errors than previous methods, especially at high noise densities, indicating it effectively
The document discusses the challenges and current solutions of cyber physical systems. It begins by defining cyber physical systems as systems that tightly integrate computation, networking, and physical processes. It then outlines three main challenge areas for cyber physical systems: 1) monitoring and actuation infrastructure challenges related to dependability, accuracy, efficiency, robustness, availability, and cost, 2) communication network challenges related to wiring, power/energy, mobility, data rate, security, and signal fading, and 3) computation and control operation challenges related to complexity, scalability, real-time operation, and fault tolerance. Current solutions discussed include developing common languages for dependability analysis, improving sensor accuracy, implementing energy efficient sensing, and using error control for improved data
Car Dynamics Using Quarter Model and Passive Suspension, Part III: A Novel Po...IOSR Journals
This document presents research on using a novel polynomial speed hump and analyzing car dynamics when crossing it using a quarter-car model. The study varied car crossing speed from 5-30 km/h, hump length from 3-9m, and hump height from 60-120mm. MATLAB simulation was used to analyze sprung mass displacement, maximum/minimum displacement, acceleration, and maximum speed for ride comfort. Graphs presented show the effect of hump dimensions and speed on these dynamics. The polynomial hump provided smooth kinematics for the sprung mass, meeting ride comfort standards of less than 0.8m/s^2 acceleration.
Crack Detection for Various Loading Conditions in Beam Using Hilbert – Huang ...IOSR Journals
The document discusses crack detection in beams using the Hilbert-Huang transform (HHT). It first provides background on using vibration-based methods to detect structural damage. It then describes modeling a cracked beam using finite element analysis, representing the crack as a rotational spring. Vibration analysis is performed on simply supported, fixed-fixed, free-free, and cantilever beams with cracks. HHT is applied to the transformed response to determine crack location based on changes in spatial variation. Both analytical and experimental results show good agreement with the model and that HHT is effective for analysis.
This document presents a method using clonal selection algorithm (CSA) to calculate the radius of circular microstrip antennas given the resonant frequency, height, and dielectric constant. CSA is a biologically-inspired optimization technique. The method is compared to experimental radius values from other studies and shows good agreement. Specifically, the CSA approach can determine the optimal radius value for a desired resonant frequency, providing a less computationally intensive design method for circular microstrip antennas.
Causes of Delay in Construction of Bridge GirdersIOSR Journals
This document analyzes the causes of delay in the construction of bridge girders for three spans of a major bridge across the Sabarmati River in Gandhinagar, Gujarat, India. Data was collected on the planned versus actual construction schedules. The total delay was found to be 75 days, with various activities like staging work, shuttering work, and reinforcement fixing experiencing delays. Major causes of delay included insufficient equipment capacity, lack of skilled labor, delays in design drawings, and poor site management. The contractor was found to be primarily responsible for these delays through issues like inadequate planning, site layout, and labor productivity.
This document analyzes the influence of process parameters like tool speed, feed rate, and shoulder diameter on the mechanical properties of joints fabricated using friction stir welding of aluminum 6061 alloy. Experiments were conducted with tool rotational speeds of 1950, 3080, and 4600 rpm and different feed rates and shoulder diameters. The tensile strength was highest at a tool speed of 3080 rpm, feed rate of 20 mm/min, and shoulder diameter of 20 mm. The tensile strength was most influenced by the tool speed. Overall, the optimal parameters for maximum tensile strength identified were a tool speed of 3080 rpm, feed rate of 20 mm/min, and shoulder diameter of 20 mm.
Experimental Investigation for Mechanical Properties of Aluminium Alloy Al 60...IRJET Journal
This document presents an experimental investigation of the mechanical properties of friction stir welded aluminum alloy Al 6061 joints considering different friction stir welding parameters. Specifically, it examines the effects of tool shape (taper or threaded), welding speed, and feed rate on the tensile strength, impact toughness, and microhardness of the welded joints. Experiments were conducted according to a Taguchi L8 orthogonal array design of experiments. Results indicated that welding speed had the greatest influence on tensile strength, feed rate most influenced impact toughness and microhardness, and the optimal parameters were a taper tool, 600 RPM welding speed, and 40 mm/min feed rate. These parameters produced joints with maximum mechanical property strengths.
This document summarizes a study that investigated the mechanical and metallurgical properties of friction stir welded AA1100 aluminum alloy joints. Different welding parameters were tested, including tool rotation speed (800-1400 rpm) and material positioning (advancing vs. retreating side). Microhardness, tensile, and fracture surface tests were used to evaluate the mechanical properties. Optical and SEM microscopy were used to analyze the microstructural evolution. The goal was to understand how processing parameters affect properties and defect development in similar AA1100 alloy joints.
The document discusses multi response optimization of friction stir welding (FSW) parameters for aluminum alloy AA6105 using the Taguchi method. It first provides background on welding processes including FSW. It then discusses factors that affect FSW quality like rotational speed, welding speed, and tilt angle. The document proposes using an L9 orthogonal array experiment with three control factors and mechanical properties and microstructure as response variables. The methodology involves conducting experiments, applying Taguchi analysis and ANOVA to optimize parameters for properties like tensile strength and hardness. The research aims to minimize defects and improve joint quality of AA6105. Equipment for FSW and response testing is also detailed.
Joining of Al(6061-T6) and Brass(IS319) by using EN19 Circular Profile Tool t...IRJET Journal
The document summarizes research on joining aluminum alloy Al6061-T6 and brass alloy IS319 through friction stir spot welding (FSSW) using an EN19 circular profile tool. Key findings include:
- FSSW was used to join Al6061-T6 to IS319 specimens and IS319 to Al6061-T6 specimens in lap joint configuration. The IS319 to Al6061-T6 joint showed better results.
- Process parameters like rotational speed of 900 RPM, feed rate of 38mm/min, and depth of cut of 3.5mm were used.
- Chemical compositions, mechanical properties, and microstructures of the aluminum, brass, and EN19 steel tool
IRJET- Friction Stir Welding of AA5052& AA6061 Aluminium Alloy by using T...IRJET Journal
This document discusses friction stir welding of dissimilar aluminum alloys AA5052 and AA6061 using Taguchi methods to optimize welding parameters. AA5052 and AA6061 plates were welded using various tool rotational speeds, transverse feeds, and tilt angles. Tensile testing showed the highest strength of 211MPa occurred with a rotational speed of 700rpm, transverse feed of 110mm/min, and tilt angle of 2 degrees. Taguchi analysis identified tilt angle as the most important parameter, with increased tilt angle improving tensile strength and elongation. Overall, friction stir welding was able to successfully join the dissimilar aluminum alloys.
Study and Analysis of the Fatigue Behaviour of Friction Stir Butt Welded Dis...IRJET Journal
1) The study analyzed the tensile strength and fatigue behavior of friction stir butt welded dissimilar aluminum alloys AA6082 and AA5754.
2) Fatigue tests showed the dissimilar welds had lower tensile strength and fatigue strength than the base materials AA6082 and AA5754, but comparable strength to AA5754.
3) The fatigue performance of the AA6082 and AA5754 friction stir welded joints showed a shallower stress-life (S-N) curve with improved fatigue performance at lower stress ranges.
FRICTION STIR WELDING OF AA6063- EXPERIMENTATION AND TESTINGijiert bestjournal
Generally,for joining process for soft materials s uch as aluminum alloys and also for hard materials like steels friction stir welding is usedas it avoids ma ny of the common problems obtained in fusion weldin g. Also if we gone through joining of aluminum alloys could be usually faced problems in many cases available in various fields like automotive,aerosp ace,ship building industries,electronics etc. whe re fusion welding is not possible due to large differe nce in physical and chemical properties of the components to be joined. Mainly the problems occurr ed in the welding processes like porosity formation,solidification cracking,and chemical reaction may arise during fusion welding of dissimilar materials . Even if good welded joints may be obtained in some limited cases with special attentions to the joint design and preparation,process parameters and fill er metals. For avoiding the drawbacks of fusion welding friction stir welding (FSW) seems to be a v ery reliable technique as it permits welding of aluminum alloys.To avoid the majorly obtained healt h defects observed during traditional welding methods or fusion welding it can be used. The produ ctions of ultraviolet rays and the gases produced i n the process which are harmful to human beings are minim ized to large extent. The parts produces in FSW of aluminum alloys have been becoming increasingly sig nificant in industrial applications because of thei r technical and economicbenefits.
Ahmed ibrahim razooqi -- study the microstructure and mechanical properties ...ahmed Ibrahim
Ahmed Ibrahim Razooqi ---
Study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3.
Friction stir spot welding-FSSW has been suggested as effectual process to welding difficult materials such as dissimilar materials and
thin sheet of metal alloys. In this study, using dissimilar materials were welded carbon steel-1006 on upper plate and aluminum alloy
AA2024-T3 on lower plate. Macrostructure, micro-structural analysis and mechanical properties of the joints are done. The effect of
penetration depth, dwell time and spindle speed on tensile shear load are investigated with invariable of other parameter during welding
process. The maximum tensile shear load (3.31KN) was occurred when using 0.4mm of penetration depth, 10 sec of dwell time and 1400
rpm of spindle speed. Also, two type of failure shape was observed interfacial fracture of carbon steel sheet and pull -out fracture of
AA2024-T3 sheet.
Research Inventy : International Journal of Engineering and Scienceinventy
esearch Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Effect of Process Parameters of Friction Stir Welded Joint for Similar Alumin...IJERA Editor
This document discusses optimizing the process parameters for friction stir welding (FSW) of similar aluminum alloy H30. Experiments were conducted using a Taguchi L9 orthogonal array with rotational speed, travel speed, and axial force as parameters. Tensile tests found strengths ranged from 32-80 MPa. Analysis of variance and signal-to-noise ratios identified axial force as the most significant parameter, with a strength-optimized level of 6000N. Rotational speed of 1600 RPM and travel speed of 20 mm/min also improved strength. The study aims to determine optimum parameters for high strength FSW joints of aluminum alloy H30.
Effect of Process Parameters of Friction Stir Welded Joint for Similar Alumin...IJERA Editor
This document discusses optimizing the process parameters for friction stir welding (FSW) of similar aluminum alloy H30 joints. Experiments were conducted using a Taguchi L9 orthogonal array with rotational speed, travel speed, and axial force as parameters. Tensile tests showed that maximum strength was achieved at 1600 RPM, 20 mm/min travel speed, and 6000N axial force. Analysis of variance identified axial force as the most significant parameter. The study aims to determine optimum parameters for high joint strength using Taguchi methodology.
Experimental Investigations of Friction Stir Welding (FSW) on Al 6061 : A Cas...IRJET Journal
This document summarizes an experimental study on friction stir welding (FSW) of aluminum alloy 6061. The study used a milling machine to conduct FSW trials with different tool pin profiles at various welding parameters. Initial trials failed due to tool breakage. Failure analysis found the main causes were tool material, rpm, and tool profile/vibrations. Modifying the tool to a tapered, threaded pin profile and increasing rpm to 1200 led to a successful weld with tensile strength of 66MPa, demonstrating FSW is possible on conventional machine tools. The study explored using FSW to join common aluminum alloys for applications like automotive and construction.
Experimental Analysis to Optimize the Process Parameter of Friction Stir Weld...IRJET Journal
This document presents an experimental analysis to optimize the process parameters of friction stir welding (FSW) for aluminum alloy AA6082. The researchers conducted FSW experiments using different combinations of tool rotation speed, tilt angle, and welding speed. Tensile strength results of the welded joints were analyzed using Taguchi methods and particle swarm optimization to determine the optimal parameter settings. Specifically, a central composite design was used with three factors at three levels each to evaluate the effects of the FSW parameters on tensile strength. The goal of the research was to develop relationships between FSW variables and tensile/yield strength and identify the best settings for maximizing strength in single and multi-pass welds of AA6082 aluminum alloy.
An Experimental Investigation on Mechanical Properties of Friction Stir Weldi...IRJET Journal
The document presents an experimental investigation on the mechanical properties of friction stir welding of aluminum alloy 6061-T6 and brass IS319 using EN19 tools with circular and taper profiles. Friction stir welding is a solid-state joining process that generates heat through friction between the rotating tool and workpieces.
The experiment was conducted on a milling machine using EN19 tools with circular and taper profiles to weld aluminum and brass plates. The welded joints were tested for tensile strength, yield strength, and hardness. The taper profile tool achieved a tensile strength of 108.5 N/mm2, yield strength of 76.05 N/mm2, and Vickers hardness of 51.73 HV. The circular
Various Parameter Effects on Friction Stir Welding- A ReviewIRJET Journal
This document reviews the effects of various parameters on friction stir welding. It summarizes research that has studied how welding parameters like rotational speed, travel speed, tool geometry, and plunge depth impact the quality of friction stir welds. The document also reviews studies on double-sided friction stir welding and how parameters like shoulder diameter and plunge depth influence mechanical properties of the welded joints. Overall, the review examines how process parameters can be optimized in friction stir welding to produce welds without defects and with improved mechanical properties.
Investigation on Mechanical Properties of AL6061 Alloy Processed by FSWijtsrd
The aim of this experiment was to improve the mechanical properties of 6061 aluminium alloys by friction stir processing FSP , a solid-state technique for micro structural modification using the heat from a friction and stirring. The Aluminium alloy 6061 is widely used in the fabrication of lightweight structures with high strength-to-weight ratio and good corrosion resistance. Welding is main fabrication method of 6061 alloy for manufacturing various engineering components. Friction stir welding FSW is a recently developed solid state welding process to overcome the problems encountered in fusion welding. This process uses a non-consumable tool to generate frictional heat on the abutting surfaces. The welding parameters, such as tool pin profile, rotational speed, welding speed and axial force, play major role in determining the micro structure and corrosion resistance of welded joint. In this work a central composite design with two different speeds, traverse speeds and Four tools has been used to minimize the experimental conditions. B. S. Bharadwaj | N. Phani Raja Rao "Investigation on Mechanical Properties of AL6061 Alloy Processed by FSW" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-6 , October 2018, URL: http://www.ijtsrd.com/papers/ijtsrd18802.pdf
Effect Of Process Parameters On Mechanical Properties Of Friction Stir.Welded...IJERA Editor
Friction Stir Welding (FSW) is an advance joining process for different similar and dissimilar materials. It is
commonly used for joining of Aluminum alloys. However it is necessary to overcome some challenges for its
wide-spread uses. Tool design and the selection of process parameters are critical issues in the usage of this
process. This study focuses on the process parameters that is required for producing effective friction stir
welding of two similar aluminum alloys (AA6101T6 to AA6101T6) and dissimilar Aluminum alloys
(AA6101T6 alloy to AA6351T6) . Three different tool diameters such as 20 mm, 25 mm and 30 mm with three
different tool rotational speeds such as 600 rpm, 800 rpm and 1200 rpm have been used to weld the joints. The
welded samples were tested for mechanical properties as well as microstructure. It was observed that 30 mm
tool gives better weld quality for friction stir welding of similar aluminum alloy but 25 mm tool with 1200 rpm
rotational speed gave satisfactory weld quality for friction stir welding of dissimilar aluminum alloys. It is one
of the important welding process that can adopted for welding of aluminum alloys with excellent mechanical
properties. The results were confirmed by further experiments.
IRJET - Characteristics of Butt Joint Produced by Friction Stir Welding ProcessIRJET Journal
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20240609 QFM020 Irresponsible AI Reading List May 2024
A1303070106
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13, Issue 3 Ver. VII (May- Jun. 2016), PP 01-06
www.iosrjournals.org
DOI: 10.9790/1684-1303070106 www.iosrjournals.org 1 | Page
Optimization of the Process Parameters of Friction Stir Welded
Aluminum Alloys for Maximum Tensile Strength
M.S.Srinivasa Rao1
, Dr.B.V.R.Ravi Kumar 2
, Dr. M. Manzoor Hussain3
1
Assistant Professor, Department of Mechanical Engineering ,VNRVJIET, Hyderbad-500 090 Telangana, India.
2
Principal, VITS College of Engineering, Sontyam, Visakhapatnam-531 173, Andhra Pradesh,India.
3
Principal, JNTUH College of Engineering Sultanapur, Sultanapur(V), Hyderabad-502 293, Telangana, India
Abstract: The friction stir welding (FSW) process is an innovative technique to join metals in the plastic state
thus not reaching the liquid state as it happen in traditional welding process. This feature of the FSW proved
that a modification can be done on the fatigue behavior and strength of the welding joints so, some of the
leading companies are adopted this process for the manufacturing of Automotive, locomotive, shipping &
aerospace. Experiments are conducted here, with a tool having a tapered square tool pin of 0.3mm clearance.
The process parameters are optimized by using Taguchi technique based on Taguchi’s L9 orthogonal array.
Experiments have been conducted based on three process parameters, namely, the tool rotational speed, tool tilt
angle and travel speed. Tensile strength has been predicted for the optimum welding parameters and their
percentage of contribution in producing a better joint is calculated, by applying the effect of the signal-to-noise
ratio and analysis of Variance. Based on the study, the tool tilt angle is found to be the most significant variable
over the other process parameters. The optimum tensile strength predicted through ANOVA is 285MPa.
Keywords: FSW, Aluminum Alloys, Tensile strength. Taguchi technique
I. Introduction
Friction stir welding (FSW) [1] is solid state thermo- mechanical joining process in which bonding
between two parts occurs by severe plastic deformation of adjacent interfaces under conditions of hydrostatic
pressure. Peak temperature during FSW process may be well below the melting temperature of welded material,
lessening typical undesirable effect of welding processes. This joining technique is an excellent choice for
aluminum alloys which are used in aerospace and automotive applications due to some of its outstanding
qualities such as, better dimensional stability, preservation of base material properties, resistance to hot cracking
etc.[2-4].
In FSW, a non- consumable rotating tool moves along the weld seam with a pin immersed into the
work-piece. The conventional FSW tool is comprised of (a) shoulder and (b) pin, where the shoulder
predominantly generates frictional heat and prevents the expulsion of material from the weld zone. The role of
FSW tool pins is to provide sufficient plastic deformation to cause bonding across any pre-existing interfaces
while transporting material to positions behind the tool. Right after the invention of friction stir welding by TWI
in 1991, efforts have been made towards designing FSW tool pins [1, 5-9] in order for the process to be
flourished over a range of manufacturing applications. However, tool geometry studies are necessarily limited as
the potential variation in geometry is essentially infinite. Since instinctive perceptions are employed for most of
the tool designs which are typically based on empirical knowledge [10], process parameters and tool parameters
may vary greatly in FSW of aluminum alloys. Consequently, numerous efforts have been devoted to understand
the relationship between tool parameters (including geometric shape, dimensions and thread features) and
mechanical-microstructure properties of different alloys within a wide range of welding conditions [11-16].
FSW tool pins are often featured with thread forms. A complex pin is designed with thread forms having
different thread interruptions such as flats or flutes [9, 15-17]. However, vertical movements of material during
FSW were presumed to be predominated by helical features in tool pin [18-19]. Tool pin geometries and
features are one of the important process control parameters in FSW that influence material flow which in turn
affect joint efficiency. Differences between base metal properties of different aluminum alloys also contribute to
different material flow and different process response variables for identical friction stir welding control
parameters including tool geometry. Considering medium strength 6xxx series and high strength 7xxx series
aluminum alloys, resistances to deformation of 6xxx alloys are less compared to 7xxx series alloy while thermal
conductivity is greater for the lower alloyed 6xxx series. These properties lead to a weldability advantage of
6xxx over 7xxx series alloys.
2. Optimization of the Process Parameters of Friction Stir Welded Aluminum Alloys for Maximum…
DOI: 10.9790/1684-1303070106 www.iosrjournals.org 2 | Page
II. Taguchi Method
The Taguchi method is very effective, because it is simple to carry on the design and its approach is
very systematic to provide good quality and low cost in manufacturing [20]. The main aim of the Taguchi
method is to analyze the statistical data, which has been given as an input function to produce an optimum
result. The effect of the combination of the input functions as a result is produced by the S/N ratio and mean
response [21]. The strength of the weld is varied by the parameters such as the tool rotating speed, tool tilt angle,
depth of penetration, dwell time and travel speed. Among these input parameters, rotating speed, tool tilt angle
and travel speed are taken and the other parameters are maintained constant. The input parameters are entered in
the array table with the output characteristics as the average tensile strength. Hence the Taguchi technique is
applied to a self analysis of the high strength material based on the tensile strength.
MINITAB software is used for the statistical analysis, how to form a combination of input parameters
and to find out most significant combination [22]. Process parameters are control factors which initiate
variability in the process are the noise factors. In a Taguchi designed experiment, the noise factors are
manipulated for the variability to occur, and from the results optimal control factors that make the process
robust, can be identified. The Signal to Noise ratio (S/N) indicates the control factors settings that minimize the
effect of the noise factors.
The Taguchi method has been implemented using MINITAB software, which includes the S/N ratio
and ANOVA. Through ANOVA the contribution of the individual parameter in making better FSW welds can
be identified. The response for the signal to noise ratio gives the most influencing parameter. Through the mean
plots of the S/N ratio and mean response, the optimum parameter has been identified.
III. Material and Experimental Work
The present investigation uses a IS:65032-T6 aluminum alloy, and find its application in aerospace as
structural members and storage tanks. The rolled plates of 5mm thickness, IS:65032-T6 aluminum alloy, have
been cut into the required size 150mm x 100mm by power hack saw cutting and milling. Square butt joint
configuration has been prepared to fabricate the FSW joints. The initial joint configuration is obtained by
securing the plates in position using mechanical clamps. The direction of welding is normal to the rolling
direction. Single pass welding procedure has been followed to fabricate the joints. A non-consumable tool has
been made of H13 tool steel used to fabricate the joints its dimensions are shown in Fig.1. The chemical
composition of tool material and the base material are presented in Table.1 & 2 respectively. The position
controlled Friction Stir Welding machine was used to fabricate the joints.
Table.2. The chemical composition of base metal
Al Cu Mg Si Fe Mn Zn Ti Cr
97.100 0.224 0.916 0.545 0.534 0.362 0.245 0.016 0.005
According to the L9 orthogonal array three experiments in each set of process parameters have been
performed on IS:65032-T6 plates. The three factors used in this experiment are the rotational speed, tool tilt
angle and travel speed. The factors and the levels of the process parameters are presented in Table.3 and these
parameters are taken based on the trials to weld the FSW of aluminum alloys. The experiment notation is also
included in the L9 orthogonal array which results in additional column, in order to represent the parameters, as
presented in Table.4. The experiments are performed on a FSW machine, it is a well known factor at higher
3. Optimization of the Process Parameters of Friction Stir Welded Aluminum Alloys for Maximum…
DOI: 10.9790/1684-1303070106 www.iosrjournals.org 3 | Page
rotating speed, FSW produces high heat input and these three levels were selected as low, medium, and high
speed. Beyond the tool tilt angle of 2° the pin pierces out the plasticized material for the thickness of 3mm and
hence 0°, 1° and 2° tool tilt angle were taken. The FSW butt joint weld being performed on a aluminum plates
needs careful experimentation, and hence the tool is plunged slowly into the work piece, till the tool shoulder
comes in contact with the surface of the work piece. When the tool is inserted the stirring action starts to occur,
and only the pin penetrates deep into the work piece while tool shoulder touches the top surface. Frictional heat
occurs along with the stirring action. Twenty seconds dwell time is given before start of each welding, and then
automatic feed is given. According to the guidelines of American Society for Testing of Materials(ASTM) the
tensile specimens are prepared as shown in Fig.2. The tensile tests for 18 specimens are conducted and they
yielded a variety of results. A sample tensile specimen, before and after the failure as shown in Fig.3. (a) & (b).
Most of the specimens tensile failure occurred in between the regions of HAZ and the base metal. FSW joints of
aluminum alloy have been welded, and the average tensile strength of the two specimens from the same joint
was obtained and is presented in Table.5. It reveals that the FSW parameters do not lead to a significant
variation, and hence, the ANOVA is used to find the optimum process parameter.
Table.3. Factors and the Levels of the process parameters
Factors Levels
1 2 3
A, Rotational speed (rpm) 1000 1300 1600
B, Tool tilt angle (°) 0 1 2
C, Travel speed (mm/min) 60 80 100
Table.4. Experimental layout of L9 Orthogonal array
SI No. Experiment’s notation Friction stir welding parameters level
A
Rotational speed (rpm)
B
Tool tilt angle (°)
C
Travelspeed (mm/min)
1 A1 1 1 1
2 A2 1 2 2
3 A3 1 3 3
4 B1 2 1 2
5 B2 2 2 3
6 B3 2 3 1
7 C1 3 1 3
8 C2 3 2 1
9 C3 3 3 2
Fig.2. Tensile test specimen (ASTM E8M-04)
Fig.3. Tensile specimen (a) before failure (b) after failure
4. Optimization of the Process Parameters of Friction Stir Welded Aluminum Alloys for Maximum…
DOI: 10.9790/1684-1303070106 www.iosrjournals.org 4 | Page
Table.5. The input parameter of orthogonal array and the output characteristics
Experimental number
Input Parameters Output characteristic
Average tensile
strength(MPa)
Rotational speed
(rpm)
Tool tilt angle
(°)
Travel Speed
(mm/min)
A1 1000 0 60 275
A2 1000 1 80 279
A3 1000 2 100 274
B1 1300 0 80 276
B2 1300 1 100 278
B3 1300 2 60 282
C1 1600 0 100 271
C2 1600 1 60 284
C3 1600 2 80 277
IV. Results and discussion
3.1 Mean and Signal to Noise ratio
The Mean and signal to noise ratio are the two effects which influence the response of the factors. The
influencing level of each selected welding parameter can be identified. The tensile strength of the FSW weld is
taken as the output characteristic. The response table for the S/N ratio shows that the tool tilt angle ranks first in
the contribution of good joint strength, while travel speed and rotational speed take the second and third ranks.
The same trend has been observed in the response table of the mean which is presented in Tables.6 &7
respectively. The response plots for the S/N ratio and mean are shown in Fig. 4 & 5. The tensile strength is
estimated to be the maximum at1300 rpm rotation speed, 1° tool tilt angle and 60 mm/min travel speed; which is
optimal from the plots obtained.
Fig.4. Main effect plot for S/N ratio
Fig.5. Main effect plot for Mean
Table.6. Response table for Signal to Noise Ratio
Level Rotational speed Tool tilt angle Travel speed
1 48.82 48.75 48.95
2 48.90 48.95 48.86
3 48.86 48.87 48.77
Delta 0.08 0.20 0.19
Rank 3 1 2
5. Optimization of the Process Parameters of Friction Stir Welded Aluminum Alloys for Maximum…
DOI: 10.9790/1684-1303070106 www.iosrjournals.org 5 | Page
Table.7. Response table for Mean
Level Rotational speed Tool tilt angle Travel speed
1 276.0 274.0 280.3
2 278.7 280.3 277.3
3 277.3 277.7 274.3
Delta 2.7 6.3 6.0
Rank 3 1 2
3.2 Analysis of Variance
ANOVA is done in MINITAB software. The main aim of the analysis is to estimate the percentage of
the individual contribution of the welding parameter on the tensile strength of the weld, and also give accurately
the combination of the process parameters. Individual optimal values for the process parameters and their
specified performance characteristics can be obtained. The relative importance of the welding parameters is
presented in Table.8. The analysis of variance for tensile result shows that the tool tilt angle is the most
significant parameter with a percentage of 47.39%, followed by the travel feed of 42.18% and rotation speed of
7.81%.
The optimum parameter obtained can be due to the two following possibilities; either the combination
of the process parameters as prescribed may be present in the experimental combination, or may not be present
in the combination. The optimum parameter for higher tensile strength obtained by the Taguchi method is
presented in Table.9. With the tool tilt angle the material is pushed and stirred along the path of travel direction,
but without the tool tilt angle only the normal stirring action takes place. Inclination of the tool thus helps to
provide a good plastic deformation at the weld zone, and better material flow can be achieved. The combination
of process parameters of 1300 rpm tool rotational speed, 1° tool tilt angle and 60 mm/min travel speed has been
predicted under the ultimate tensile strength of 285MPa.
Table.8. Analysis of variance (ANOVA)
Source DF Adj. SS Adj. MS F P Percentage of contribution
Rotating speed 2 10.667 5.333 4.00 0.200 7.81
Tool tilt angle 2 60.667 30.333 22.75 0.042 47.39
Travel speed 2 54.000 27.000 20.25 0.047 42.18
Error 2 2.667 1.333 2.08
Total 8 128.000
Table.9. Optimized result obtained from ANOVA – Minitab
Rotational speed
(rpm)
Tool tilt angle
( ° )
Travel speed
(mm/min)
Ultimate tensile
Strength (MPa)
Taguchi method 1300 1 60 285
3.3 Experimental result
The essential joint strength obtained from the optimization study is verified by conducting experiment,
using the optimal combination of the process parameters (tool rotation speed 1300 rpm, 1° tool tilt angle and 60
mm/min traverse speed). An experiment is conducted with the optimum combination, and the average strength
of the weld obtained with the process parameters is found to be 288MPa and this value is close to the predicted
value. The ultimate tensile strength of the base material is 308MPa, hence the given set of parameters and levels
Rotational speed 1300 rpm, 1° tool tilt angle and 60mm/min is the best condition to attain the maximum tensile
strength.
When the process parameters are observed individually as per the contribution, each parameter shows a
different characteristic behavior. If the rotating speed increases, then the rate of heat generation also increases in
the stir zone. Then, the optimized value should be higher speed, but here it has resulted in a moderate speed,
which indicates that sufficient heat alone is required for plasticized material flow. The tool tilt angle favors the
material movement towards the travel direction and also the mixing of the plasticized material flow in the weld
zone.
V. Conclusions
To find the optimal parameters the Taguchi technique has been used in this investigation. The following
concluding remarks can be made from the present study:
The Analysis of Variance for the tensile result concludes that the tool tilt angle is the most significant
parameter with a percentage of 47.39% followed by the travel speed of 42.18% and rotation speed of
7.81%.
The optimum combination of parameters obtained from the main effect plot for the S/N ratio and mean is
1300 rpm rotation speed, 1° tool tilt angle and 60 mm/min traverse speed, and the tensile strength has been
6. Optimization of the Process Parameters of Friction Stir Welded Aluminum Alloys for Maximum…
DOI: 10.9790/1684-1303070106 www.iosrjournals.org 6 | Page
predicted as 285MPa. The confirmation test performed with the optimum process parameter is found to
have an average tensile strength of 288MPa, and hence optimization is useful.
The tool tilt angle favors the material movement towards the travel direction and also the mixing of the
plasticized material flow in the weld zone, hence good mechanical and metallurgical properties of the
weldments.
Acknowledgements
The authors would like to thank Dr. G. Madhusudhan Reddy Outstanding Scientist & Director,
Defence Metallurgical Research Laboratory (DMRL), Hyderabad and Dr. V. V Rao, Outstanding Scientist,
ASL, Hyderabad for material assistance from DRDO and also permission to publish this work. One of the
authors (Mr. M.S.Srinivasa Rao) express his gratitude to the Dr. K.Veerabrahmam, Scientist ‘D’, ASL,
Hyderabad also extended his gratitude to the management of VNR VJIET, Hyderabad for their continuous
support and encouragement.
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