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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

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2022

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Vol. 40, No. 1

101--115

EN

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.

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Experimental and Statistical Analysis of Possibility Sources – Rotation Speed, Clamping Torque and Clamping Pith for Quality Assessment in Friction Stir Welding

Sabry Ibrahim

Management and Production Engineering Review

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2021

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Vol. 13, No. 3

84--96

EN

This paper is the first to optimize the friction stir welding (FSW) process considering the Clamp Pitch (mm) and Clamping Torque effect using the Various combinations of parameters were constructed using factorial design and responses, resulting in a comprehensive factorial analysis. Conspicuous changes in the tensile strength, yield strength, hardness, and power profile were observed for all amalgamations of parameters. Significant parameters of the FSW process have been considered in many optimization studies, however, the effect of the Clamp Pitch (mm) and Clamping Torque (Nm) has been never studied. Three levels of three parameters were used in the experiments: Clamp Pitch, tool rotational speed and Clamping Torque. The full factorial analysis was performed, was applied as an approach for selecting the values of the Significant factors of the parameters. For each result the three key parameters were important with p-values of less than 0.05, suggesting their significance in the phase of FSW. Mathematical models built with high R-sq. and least percentage error were adequate for the investigated responses. The findings were gained by important parameter values factors of 30 mm, 1800 rpm and 70 Nm for the take into consideration parameter range for the Clamp Pitch, rotational speed and Clamping Torque respectively.

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Six sigma methodology used to improve the mechanical properties for friction stir weldingof aluminum pipes

Sabry Ibrahim

Management and Production Engineering Review

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2020

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Vol. 11, No. 1

73--78

EN

This paper presents a new welding quality evaluation approach depending on the analysis by the fuzzy logic and controlling the process capability of the friction stir welding of pipes (FSWoP). This technique has been applied in an experimental work developed by alternating the FSW of pipes process major parameters: rotation speed, pipe wall thickness and travel speed. variable samples were friction stir welded of pipes using from 485 to 1800 rpm, 4–10 mm/min and 2–4 mm for the rotation speed, the travel speed, and the pipe wall thickness respectively. DMAIC methodology (Defining, Measuring, Analyzing, Improving, Control) has been used as an approach to analyze the FSW of pipes, it depends on the attachment potency and technical commonplace demand of the FSW of pipes process. The analysis controlled the Al 6061 friction stir welded joints’ tensile strength. To obtain the best tensile strength, the study determined the optimum values for the parameters from the corresponding range.