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Underwater friction-stir welding of a stir-cast AA6061-SiC metal matrix composite: optimization of the process parameters, microstructural characterization, and mechanical properties

Sabry Ibrahim, Hewidy A. M.

Materials Science Poland

2022

Vol. 40, No. 1

101--115

It is an underlying fact for the case of the joining process especially welding to have optimized parameters to achieve joints with outstanding mechanical characteristics. In the current article, using stir-cast aluminum-based alloy (Al 6061) is stir-cast with Al 6061/5%wt. silicon carbide, Al 6061/10%wt. silicon carbide, and Al 6061/18%wt. silicon carbide was welded using an underwater friction-stir welding process. Optimum welding parameters [namely, tool rotating speed (N), welding speed (S), and silicon carbide (SiC)] are investigated using analysis of variance (ANOVA) and response surface methodology (RSM) statistical approaches. High ultimate tensile strength and microhardness were set as required characteristics of quality welds. Since there are two responses and two objectives, multiple-criteria decision-making approach-response surface methodology was performed alongside ANOVA. Optimal parameters from these statistical approaches are converged to a tool rotating speed of 1,736.36 rpm, a welding speed of 11.58 mm/min, and a SiC of 16.67%, respectively. For the current inquiry, the computed ultimate tensile strength and microhardness are 984 MPa and 89.9 HV, respectively, and these values are congruent with the findings of effectiveness studies. It is deduced from this study that the optimal parameters are convergent irrespective of the two used techniques for the investigated experimental data.

Investigation and optimization of friction stir welding process parameters of stir cast AA6082/ZrO2/B4C composites

Umar Mohamed J., Palaniappan Pl. K., Maran P., Pandiyarajan R.

Materials Science Poland

2020

Vol. 38, No. 4

715--730

In the present investigation, aluminium-based alloy (AA6082) is stir-casted with 3 % ZrO2 and 5 % B4C reinforcement particulates to fabricate Aluminium Metal Matrix Hybrid Composites (AMMHCs) which are further friction-stir welded at different welding conditions to develop a welded joint with optimum ultimate tensile strength (UTS) and microhardness. This newly developed AMMHC will find its specific application as bulkhead partitions in the hull of a ship due to its excellent properties, such as lower weight, higher specific strength, superior resistance to wear, and lower thermal expansion coefficient than that of AA6061 and AA5083 composites. The friction-welded butt joints performance of AA6082/3%ZrO2/5%B4C is generally determined by varying the FSW process parameters such as tool rotational speed (TRS), welding speed (WS), axial load (AL), tool tilt angle (TTA), tool pin profile (TPP), shoulder diameter (SD), etc. In the present work, the empirical relationships are established between parameters highly influencing FSW process (TRS, WS, and AL) and their responses (UTS and weld nugget microhardness (WNH)). The desirability approach is employed for predicting the optimal UTS and WNH. The corresponding values of input process parameters are TRS of 1030.95 rpm, WS of 38.5 mm/min, and AL of 5.88 kN. The calculated UTS and WNH for the present investigation are 239.98 MPa and 94.2 HV, respectively, and these values are consistent with the results of validation experiments.