Transactions of The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy, materials engineering, physical, chemical and mechanical metallurgy, welding science and technology, surface engineering and characterisation, materials development, thermodynamics and kinetics, materials modelling and to other allied branches of metallurgy and materials engineering.

Transactions of the Indian Institute of Metals

In this paper, parameter optimization of FSW of cryorolled AA2219 alloy was carried out to obtain defect free weld joint with maximum weld strength. To achieve this, artificial neural network (ANN) was used to model the relationship between the input parameters and the mechanical and corrosion properties (output) of the weld joints. The optimal FSW parameters were determined by genetic algorithm (GA). The feasible solution of the GA was tool rotational speed of 1005 rpm, tool travel speed of 20 mm/min and tool tilt angle of 3°. The feasible parameter was used to weld and check the ability of the parameter to produce better weld joint than the L9 orthogonal array parameters. The weld, subjected to the confirmation test, was investigated by means of metallurgical, mechanical, and corrosion testing. This process reduces the costs associated with trial runs to obtain optimal parameters and also the production cost of the cryorolled (CR) plate which is high.

Parameter optimization of friction stir welding of cryorolled AA2219 alloy using artificial neural network modeling with genetic algorithm

In the present study, dissimilar alloys such as Mg-AZ31B and Al-AA6061 were joined by friction stir welding using different rotational (560, 710, 860 and 1010 rpm) and transverse speeds (16 and 25 ...

Effect of friction stir welding process parameters on Mg-AZ31B/Al-AA6061 joints

Friction stir welding is a solid-state welding technique for joining similar and dissimilar material. Bobbin tool friction stir welding (BTFSW) is a variant of the conventional friction stir welding process (CFSW). Compared with conventional FSW, BTFSW eliminates all limitations of CFSW using a two shoulders configuration. Now, the need has arisen to review the work done on BTFSW to provide broader aspects of the technique to researchers. This paper aims at providing comprehensive insight on the BTFSW. The paper pays critical attention to tool material selection, design features of shoulder and pin surfaces, microstructure evolution, mechanical characterisation, derivatives, and challenges in this technique. Further, welding defects and future scope of BTFSW are also addressed in this paper.

Bobbin tool friction stir welding: a review

This current work considers the utilization of the completely Lagrangian technique, smoothed particle hydrodynamics to improve the 3D finite element model for numerical analysis of the friction stir welding (FSW) in the air and underwater conditions. This technique was primarily applied to simulate fluid motion because of various advantages compared to conventionally grid-based methods. Newly, its usage has been developed to analyze the metal-forming analysis. The temperature history, strain and stress distributions during the FSW process in the air, as well as underwater, were considered. Besides the cooling influence, the effect of traveling speed, friction coefficient, mesh size and the mass scaling technique to find the converged model and decrease the CPU time were studied. The improved model is confirmed by comparing the numerical welding temperature with experimental outcomes. There was close compatibility between finite element analysis and experimental results. The conclusions indicated that the lower peak temperature was achieved due to higher cooling effect in underwater welding in comparison with conventional welding. Moreover, the peak temperature and strain rate decreased as traveling speed increased for both welding conditions, while stress values increased.

Numerical analysis of cooling and joining speed effects on friction stir welding by smoothed particle hydrodynamics (SPH)

Al/SiC-reinforced metal matrix composite is widely used in weight-sensitive applications such as portable and integrated circuit devices. The presence of SiC particles in aluminum alloys enhances material properties like thermal conductivity, density, and tensile strength. Reinforced aluminum matrix composite can be welded by friction stir welding (FSW) process. This investigation mainly focuses on optimizing the welding parameters of friction stir welded AA7075 with SiC reinforcement particle. The welding parameters considered are spindle speed, travelling speed, downward force, and percentage of SiC added to AA7075. The experiments are designed using response surface methodology (RSM). The responses considered are ultimate tensile strength and percentage elongation. Regression models are developed for the single responses and the results are analyzed using analysis of variance. Fuzzy grey relational analysis approach is then used to optimize the FS welding parameters by considering multiresponses. Highe...

R. Parameshwaran

Papers

Multiresponse Optimization of FSW Parameters for Cast AA7075/SiCp Composite