International Journal of Advance Engineering and Research Development Volume 4, Issue 2, February -2017

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1 Scientific Journal of Impact Factor (SJIF): 4.72 e-issn (O): p-issn (P): International Journal of Advance Engineering and Research Development Volume 4, Issue 2, February Optimization of process parameters for friction stir welded aluminium alloy AA7075 using full factorial method 1 Mr. Jignesh J. Patel, 2 Dr. Mohammad Israr 1 PhD Scholar, RAI University- Ahmedabad, 2 Principal, Dungarpur College of Engineering and Technology, Dungarpur- Rajasthan. ABSTRACT: Friction stir welding is a recent emerging solid state joining technique used to join high strength aluminium alloy. This present work focused to evaluate the effect of process parameters such as tool rotational speed, welding speed and tool tilt angle on flow stress and yield strength of friction stir welded AA7075 joints. The modeling and simulation has been carried out by using Hyper Works 14.0 simulation software. The optimum process parameters were determined by the Taguchi full factorial parametric design approach. 1.0 INTRODUCTION Friction Stir Welding (FSW) is a solid state joining technique invented and patented by The Welding Institute (TWI) in 1991 for butt and lap welding of ferrous and non ferrous metals and plastics [1]. Since its invention, the process has been continually improved upon as its scope of application becomes expanded. FSW is a continuous process that involves plunging a portion of a specially shaped rotating tool between the abutting faces of a joint. The relative motion between the tool and the substrate generates frictional heat that creates a plasticized region around the immersed portion of the tool. In addition, the shoulder prevents the plasticized material from being expelled from the weld, therefore, the tool is moved relatively along the joint line, forcing the plasticized material to coalesce behind the tool to form a solid phase joint [1]. The inserted picture also depicts the tool shoulder and the tool pin. The tool pin is sometimes referred to as the probe. The advancing side is on the right, where the tool rotation direction is the same as the tool travel direction (opposite the direction of metal flow), while the retreating side is on the left, where the tool rotation is opposite to the tool travel direction (parallel to the direction of the metal flow). The tool serves three primary functions; the heating of the work piece, the movement of material to produce the joint, and the containment of the hot metal beneath the tool shoulder [1]. The heat generated during the FSW process is often assumed to occur predominantly under the shoulder; due to its greater surface and to be equal to the power required to overcome the contact forces between the tool and the work piece [3]. To an extent, the heat input into the welds increases as the shoulder diameter increases [4]. The three different shoulder diameters used in this research study were chosen to vary the heat input into the welds while varying the process parameter settings. The benefits of FSW process as a technology include: low distortion, greater weld strength compared to the fusion welding process, little or no porosity, no filler metals, no solidification cracking, no welding fumes or gases, improved corrosion resistance, and lower cost in production applications. Because of the many demonstrated advantages of FSW over the fusion welding techniques, the commercialization of FSW is progressing at a rapid pace [5]. FSW is considered to be the most significant development in metal joining techniques in decades; and it is, in addition, a green technology due to its energy efficiency, environmental friendliness and versatility. When compared to the conventional welding methods, FSW consumes considerably less energy and no harmful emissions are created during the welding process [6]. Different microstructural zones exist after FSW, this include: the Heat Affected Zone (HAZ) which is a region that lies closer to the parent materials, the materials have experienced a thermal cycle that has modified the microstructure and or the mechanical properties. The Thermo Mechanically Affected Zone (TMAZ) is a zone where the FSW tool has plastically deformed the material while the Stir Zone (SZ) also referred to as the Weld Nugget (WN) is a fully recrystallized region; it refers to the zone previously occupied by the tool pin. This microstructural characterization is credited to P. L. Threading [7]. From the reported literature, it is observed that influence of AA alloys on mechanical properties was studied. Hence the objective of present investigation is to study the influence of process parameters on mechanical properties of AA alloys fabricated via FSW and obtain the optimum combinations using full factorial method were adopted to analyze the effect of each processing parameters (i.e Tool tilt angle, welding speed and tool rotation speed) for optimum flow stress and yield strength. 2.0 EXPERIMENTAL PROCEDURE In this work AA7075 with dimension of 300 mm 100 mm 6mm plates with chemical composition of the AA7075 is shown in Table 1were selected to perform virtual FSW experiment using Hyper Works The tool geometry was selected with cylindrical pin having a shoulder diameter (D=17mm), shoulder length (L=70mm), pin diameter (d=6mm) and pin length (l=5.4mm). Physical and thermal properties of AA 7075 are shown in Table 2. The parameters identified All rights Reserved 310

2 investigation are tool tilt angle, welding speed, tool rotation speed. The selected process parameter and their levels are shown in table 3.. Table 1. Chemical composition of AA7075 Element Mg Mn Zn Fe Cu Si Cu Al Wt% Bal Table 2. Physical & Thermal Properties of AA7075 Property Values Density 2810 Kg/m3 Melting Point 635 C Modulus of Elasticity 40 GPa Poisons Ratio 0.35 Thermal Conductivity 173 W/m-K Specific Heat Capacity 960 J/Kg-K Table 3 Process parameter and their levels. Symbol Welding Parameter Level 1 Level 2 Level 3 TA Tilt Angle WS Welding speed (mm/sec) TS Tool rotation speed(rpm) FINITE ELEMENT MODELING AND ANALYSIS OF FRICTION STIR WELDING PROCESS Altair Hyper Works 14.0 simulation tool is used for simulation and finite element analysis of friction stir welding process. This software has a thermal conduction capability and can be used for a 3-dimensional, steady-state or transient thermal analysis. Transient finite element analysis is performed considering steady state heat source. The finite element model was developed for simulation of friction stir welding. The FSW parameters considered by the simulation suit are pin diameter, pin height, pin rpm, pin tilt, translational speed, shoulder diameter and height. It is assumed that 90% of the work is converted into energy. The developed finite element model has several components with their defined name, no. of elements and ID range. Hyper Works provides an efficient interface for development of finite element model and analyzing friction stir welding with the HyperXtrude Solver. The initial temperature of the work piece is assumed equal to the ambient temperature (293K). Convection s coefficient of 30 W/m 2 K is applied at the top and side surfaces of the work piece. Since the value of conductive coefficient between the work piece and the backing plate is unknown, convective coefficient of 300 W/m 2 K can be applied to the bottom surface of the work piece. The above conditions are adopted from Colegrove [13]. Fig.1 Finite element model of friction stir welding process showing different displayed components such as tool, butt joint, HAZ, left plate and right All rights Reserved 311

3 4.0 RESULT AND DISCUSSIONS Table 4 shows the selected design matrix based on full factorial L 27 orthogonal array consisting of 27 sets of coded conditions and the experimental results for the responses of flow stress and yield strength. All these data have been utilized for analysis and evaluation of optimal parameter combination required to achieve desired quality weld within the experimental domain. Run No. Table 4: Orthogonal array L 27 of the experimental runs and results Tilt Angle Welding Speed Tool rotation Flow stress (Degree) (mm/s) Speed (rpm) (Mpa) Yield stress (Mpa) ANALYSIS OF VARIANCE Analysis of variance (ANOVA) test was performed to identify the process parameters that are statistically significant. The purpose of the ANOVA test is to investigate the significance of the process parameters which affect the flow stress and yield strength of FSW joints. The ANOVA results for flow stress and yield strength of means are given in Table 5 and 6. In addition, the F-test named after Fisher can also be used to determine which process has a significant effect on flow stress and yield stress. Usually, the change of the process parameter has a significant effect on the quality characteristics, when F is large (Table 5 and 6). The results of ANOVA indicate that the considered process parameters are highly significant factors affecting the flow stress and yield strength of FSW joints in the order of rotational speed, welding speed and tool tilt angle. It is observed from the data welding speed has significance effect on both flow stress and yield strength. Accuracy of All rights Reserved 312

4 was tested by using ANOVA. All term including TA, WS and TS were found to be significant at 95% confidence interval. The determination coefficient R 2 (0.9161) is also high, which indicates high significance of model. Table: 5 Analysis of Variance for Flow stress (Mpa) Source DF Seq SS Adj SS Adj MS F P TA WS TS Error Total S = R-Sq = 34.43% R-Sq(adj) = 14.76% Table 6: Analysis of Variance for yield stress (Mpa). Source DF Seq SS Adj SS Adj MS F P TA WS TS Error Total S = R-Sq = 91.61% R-Sq(adj) = 89.09% DF-Degrees of freedom, Seq SS-Sequential sum of squares, Adj SS-Adjusted Sum of square, Adj MS-Adjusted mean square, F-Fisher ratio, P-probability that exceeds the 95 % confidence level 4.2. OPTIMIZING THE YIELD STRENGTH PROPERTIES Analyzing data means and interaction plot for flow stress and yield strength of various process parameters, it is observed that a larger means corresponds to better quality characteristics. Therefore, optimal level of process parameter is the level of highest means. Mean for flow stress and yield strength was at maximum when rotational speed 600 rpm, welding speed 4.16mm/s and tool tilt angle is 0 degree, which is shown in figure 2 to figure 7. Fig. 2 Response plot of data means for flow All rights Reserved 313

5 Fig. 3 Interaction plot for flow stress Fig. 4 Residual plots for Flow All rights Reserved 314

6 Fig. 5 Response plot for data means for yield stress Fig. 6 Interaction plot for Yield All rights Reserved 315

7 Fig. 7 Residual plots for Flow stress 5.0 CONCLUSION Yield strength of Al alloy AA7075 has been evaluated under different processing parameters using full factorial experimental design. The Analysis of Variance for the flow stress result concludes that the welding speed is the most significant parameter followed by tool rotation speed and tilt angle. The analysis of variance for the yield strength result concludes that the welding speed is the most significant parameter followed by tilt angle and tool rotation speed. Optimum condition from main effect plot for mean and interaction plot to get good yield strength is Tool rotational speed 600 rpm, welding speed 4.16mm/s and tool tilt angle 0 degree. 6.0 REFERENCES 1. Thomas W. M, Nicholas E. D., Needham J. C., Murch M. G., Templesmith P. and Dawes C. J. Improvements relating to Friction Welding. International Patent Application, PCT/GB92/02203 (Patent) December Friction stir welding of aluminium. Online Available: Assessed May Colligan K. J. and Mishra R. S., A conceptual model for the process variables related to heat generation in friction stir welding of aluminium. Scripta Materialia.. Vol. 58, pp , Blignault C, A friction stir weld tool-force and response surface model characterizing tool performance and weld joint integrity. D.Tech dissertation, Nelson Mandela Metropolitan University, Port Elizabeth, South Africa Reynolds A. P, Friction stir welding of aluminium alloys. In: Totten GE, MacKenzie DS (eds.) Handbook of Aluminium, Volume 2 Alloy Production and Materials Manufacturing. New York, Marcel Dekker; p , All rights Reserved 316

8 6. Nandan R., DebRoy T. and Bhadeshia H. K. D. H, Recent advances in friction stir welding- Process, weldment structure and properties. Progress in Material Science, vol. 53: pp Threadgill P. L, Terminology in friction stir welding. Science and Technology of Welding and Joining. 12(4): pp , Bakes H, Benjamin D, Kirkpatrick C W. Metals Handbook. vol. 2. ASM. Metals Park: OH; 1979; Ravi N, Sastikumar D, Subramanian N, Nath A K, Masilamani V. Microhardness and microstructure studies on laser surface alloyed aluminium alloy with Ni-Cr. Materials and Manufacturing Processes 2000; 15: Devaraju A, Kumar A. Dry Sliding Wear and Static Immersion Corrosion Resistance of Aluminum Alloy T6/SiCp Metal Matrix Composite Prepared Via Friction Stir Processing. International journal of advanced research in mechanical engineering 2011; 1:2: Essam R I, Makoto T, Tishiya S, Kenji I. Wear characteristics of surface-hybrid-mmcs layer fabricated on aluminum plate by friction stir processing. Wear 2010; 268: Bendell A (1988) Introduction to Taguchi Methodology, Taguchi Methods: Proceedings of the 1988 European Conference:, Elsevier Applied Science, London, England, P. Colegrove, 3 Dimensional Flow and Thermal Modelling of the Friction Stir Welding Process, Thesis Master of Engineering Science, The University of Adelaide, January All rights Reserved 317

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