Optimization of friction stir welding process parameter in the joining of AA7075-T6/AA5083-O dissimilar aluminum alloy using response surface methodology

IF 3 2区工程技术 Q2 ENGINEERING, MECHANICAL International Journal of Pressure Vessels and Piping Pub Date : 2024-07-31 DOI:10.1016/j.ijpvp.2024.105282

Meghavath Mothilal, Atul Kumar

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Abstract

This present study is aimed to produce high-strength dissimilar joints of AA5083-O and AA7075-T6 alloys through optimization in the friction stir welding (FSW) process parameters. In this work, we have employed the response surface methodology (RSM) iteratively to generate 20 different welding process parameter combinations. These parameters are used to manufacture dissimilar weld joints, and the impact of these process parameters on the mechanical properties of the weld joints is evaluated by performing a series of mechanical tests such as tensile and microhardness. The microstructural evolution of the welded joints is studied using optical and SEM techniques. EBSD analysis is performed to understand the grain size, orientation, and changes in microstructure. The weld nugget zone reveals the presence of finer grains measured as 0.3 μm–0.7 μm. The specimen manufactured using FSW optimized process parameters of rotational speed 1100 rpm, welding speed 50 mm/min, and tool tilt angle 2° shows the ultimate tensile strength of 417 MPa, weld nugget hardness of 189 HV_0.1, and weld efficiency 80.65 %. The tensile fractured surface of specimens is also inspected using SEM to determine the mode of failure reached in the welded joints.

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利用响应面方法优化 AA7075-T6/AA5083-O 异种铝合金焊接中的搅拌摩擦焊工艺参数

本研究旨在通过优化搅拌摩擦焊（FSW）工艺参数，生产 AA5083-O 和 AA7075-T6 合金的高强度异种接头。在这项工作中，我们采用响应面方法（RSM）迭代生成了 20 种不同的焊接工艺参数组合。这些参数用于制造异种焊点，并通过执行一系列机械测试（如拉伸和显微硬度）来评估这些工艺参数对焊点机械性能的影响。使用光学和扫描电镜技术研究了焊点的微观结构演变。EBSD 分析用于了解晶粒大小、取向和微观结构的变化。焊接金刚石区域发现了 0.3 μm-0.7 μm 的较细晶粒。使用 FSW 优化工艺参数（转速 1100 rpm、焊接速度 50 mm/min、工具倾斜角度 2°）制造的试样显示出 417 MPa 的极限抗拉强度、189 HV 的焊缝硬度和 80.65 % 的焊接效率。此外，还使用扫描电子显微镜检查了试样的拉伸断裂表面，以确定焊接接头的失效模式。

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来源期刊

International Journal of Pressure Vessels and Piping 工程技术-工程：机械

CiteScore

5.30

自引率

13.30%

发文量

208

审稿时长

17 months

期刊介绍： Pressure vessel engineering technology is of importance in many branches of industry. This journal publishes the latest research results and related information on all its associated aspects, with particular emphasis on the structural integrity assessment, maintenance and life extension of pressurised process engineering plants. The anticipated coverage of the International Journal of Pressure Vessels and Piping ranges from simple mass-produced pressure vessels to large custom-built vessels and tanks. Pressure vessels technology is a developing field, and contributions on the following topics will therefore be welcome: • Pressure vessel engineering • Structural integrity assessment • Design methods • Codes and standards • Fabrication and welding • Materials properties requirements • Inspection and quality management • Maintenance and life extension • Ageing and environmental effects • Life management Of particular importance are papers covering aspects of significant practical application which could lead to major improvements in economy, reliability and useful life. While most accepted papers represent the results of original applied research, critical reviews of topical interest by world-leading experts will also appear from time to time. International Journal of Pressure Vessels and Piping is indispensable reading for engineering professionals involved in the energy, petrochemicals, process plant, transport, aerospace and related industries; for manufacturers of pressure vessels and ancillary equipment; and for academics pursuing research in these areas.