In this study, the friction stir welding between AA5083 and AA7075 is modeled using numerical methods, and the role of parameters affecting the process, such as welding speed and rotation speed on material flow, temperature, and strain, is studied. The temperature, strain, and material mixing were analyzed while welding AA7075 to AA5083 alloys using a Coupled Eulerian-Lagrangian (CEL) approach. It was discovered that the CEL approach had accurately anticipated the mixing of materials in the stir zone (SZ) by comparing the SZ of the samples fabricated experimentally and modeled by simulation. Results show that the temperature and strain increase dramatically as the rotation speed increases from 500 to 900 rev min−1. The material flow obtained from the simulation shows that with increasing rotational speed or decreasing welding speed, AA7075 is more stretched towards AA5083 in the sheet’s higher surfaces, indicating an increase in material flow intensity. Better material mixing and increased material flow allowed for the achievement of the maximum tensile strength at the welding and rotation speeds of 36 mm min−1 and 900 rev min−1.

Investigation of the effect of welding and rotational speed on strain and temperature during friction stir welding of AA5083 and AA7075 using the CEL approach

The primary goal of the study is to optimize the welding parameters using Friction Stir Welding (FSW) to join AZ31B Mg and AA 6061 alloys considering input parameters such as rotational speed, welding speed, shoulder-to-pin diameter ratio and plunge force and output parameters as peak temperature. The simulation experiment is carried out using COMSOL Multiphysics® 6.0 Software. The simulation experiment is designed using the Box-Behnken design (BBD) of Response Surface Methodology (RSM) and mathematical models were developed. The Analysis of Variance (ANOVA) is used to assess the features of the performance effectiveness of the parameters. Both direct and indirect interaction effects are investigated; the results indicate that the rotational speed is the most influential parameter when compared to other factors; as rotational speed increases consequently; there is an increase in temperature. Finally, the Artificial Neural Network was trained and tested in MATLAB software to optimize the parameters. The validation was performed to predict the minimal predicted temperature value. The confirmatory tests reveal that the predicted results are extremely close to the experimental values from the simulation.

Friction stir-welding of AZ31B Mg and 6061-T6 Al alloys optimization using Box-Behnken design (BBD) and Artificial Neural network (ANN)

Effect of Al2TiO5 Particulates on the Microstructural and Mechanical Characteristics of AA5052 Composites

This study presents the tensile strength and surface roughness resulting from friction stir welding (FSW) on the lap joint method using AA 6061 –T6. FSW is conducted by comparing three different tool pin shapes: hexagon, thread, and square. Overlap welding using the FSW method is challenging if machine parameters, such as spindle speed and feed rate, are incompatible. The experiment was conducted using a conventional milling machine with a spindle speed of 1400 -1750 rpm and a feed rate of 20 – 30 mm/min. The results show that a spindle speed of 1750 rpm and a feed rate of 30 mm/min using a square tool pin results in 83.5088 MPa ultimate tensile strength and 0.85 µm surface roughness (Ra), which is much better than hexagon and thread type tool pins. In addition, the overall results on all three tool pin shapes show that higher processing parameters increase tensile strength and surface roughness. This study revealed the effect of parameters on AA6061 –T6 and the resulting implications of mechanical strength and surface roughness.

Influence of tool pin profile on the mechanical strength and surface roughness of AA6061-T6 overlap joint friction stir welding

This paper explores the revolutionary approach of enhancing aluminum composite manufacturing through the integration of Cr2O3 reinforcement using the Friction Stir Technique. The pivotal role of the vertical milling machine in executing Friction Stir Processing (FSP) is emphasized, detailing precise parameters crucial for achieving optimal results. The even dispersion of Cr2O3 throughout the matrix is highlighted as essential for ensuring consistent mechanical and chemical properties, enhancing overall strength, durability, and resistance to corrosion. Experimental findings reveal significant improvements across multiple mechanical properties, including a remarkable 21.56% increase in tensile strength, a notable 36.89% enhancement in hardness, a significant 24.33% improvement in fatigue strength, and a substantial 29.04% increase in wear resistance. These results underscore the effectiveness of Cr2O3 reinforcement via FSP in revolutionizing aluminum composite manufacturing, offering a pathway towards the development of high-performance materials with diverse industrial applications. 

https://www.e3s-conferences.org/articles/e3sconf/pdf/2024/37/e3sconf_icftest2024_01032.pdf

Revolutionizing Aluminum Composite Manufacturing: Harnessing Cr2O3 Reinforcement via Friction Stir Technique


 Aluminum (Al) alloys are reinforced with carbides and oxides to enhance their properties. Al composites are developed to meet current automotive, shipbuilding, and aviation requirements. In the current study, aluminum 6061 is reinforced with B4C and Cr2O3 separately to fabricate Al6061 + B4C and Al 6061+Cr2O3 aluminum metal matrix composites (Al MMC). The Al composites were fabricated by stir casting with a wt % in steps of 2%, 4%, and 6%. Joining of Al MMC is essential to develop valuable components. The developed composites were welded using friction stir welding (FSW). FSW is recognized and widely used for joining Al MMC due to premium weld quality with minimum defects. The present study aims to analyze the effect of process parameters and predictive accuracy of the artificial neural network (ANN) and response surface methodology (RSM). The parameters selected for the study are tool rotational speed, tool travel speed, and reinforcement wt %. The FSW was performed based on the experimental design developed by the design expert software. Through RSM analysis, it was found that both the independent factors (tool rotational and tool transverse speed) and the interaction of factors jointly contribute to the FSW joint properties. The higher ultimate strength of 139 MPa and lower tensile strength of 48 MPa are found. As the tool travel speed increase from 20 to 25 mm\min, ultimate tensile strength increase about 59%. The average accuracy of RSM was 98.26 and of ANN was 94.86.

https://iopscience.iop.org/article/10.1088/2631-8695/acb6d1/pdf

Analysis of tensile strength on friction stir welded Al 6061 composite reinforced with B4C and Cr2O3 using RSM and ANN


 The current study investigates the exfoliation corrosion behavior of friction stir welded aluminum composite. The stir casting method was employed to fabricate chromium oxide (2 and 4% wt) reinforced Al 6061 composites. The fabricated composite samples are friction stir welded with two process parameters. The solution immersion tests were performed for two intervals per the ASTM G34 (24 hours, 48 hours), and the weight loss method was employed. The corrosion sample is analyzed by optical microscope FESEM and surface roughness. The gelatinous corrosion product formed over the surface can apply pressure over the grains resulting in the formation of pits. The intergranular corrosion (IGC) is formed by continuous penetration of the solution and the pits. The grains suffering from IGC are more susceptible to pit. The weight-loss method is not sufficient to predict the damage induced by the exco solution. Evaluating the pit depth can help to know the severity of corrosion. The measurement of the pit is difficult due to its irregular nature. The surface roughness instrument is used, and the damage is represented in average roughness (Ra) and average depth (Rz). The exposure duration and welding parameters play a significant role in corrosion. More material is lost at higher process parameters and extended hours of the test, forming higher surface deterioration.

Exfoliation corrosion susceptibility on friction stir welded aluminium 6061/Cr2O3 composite.

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Analysis of tensile strength on friction stir welded Al 6061 composite reinforced with B4C and Cr2O3 using RSM and ANN

Exfoliation corrosion susceptibility on friction stir welded aluminium 6061/Cr2O3 composite.