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Optimization of friction stir spot welding parameters for joining dissimilar AZ31B magnesium alloy and AA6061 aluminium alloy using response surface methodology
https://orcid.org/http://orcid.org/0000-0001-7044-1969
https://orcid.org/http://orcid.org/0000-0002-3997-5337
https://orcid.org/http://orcid.org/0000-0002-5207-0049
AZ31B magnesium (Mg) alloy and AA6061-T6 aluminium (Al) alloy are preferentially used in automotive industries due to its good mechanical properties, light weight, and corrosion resistance. The dissimilar welding of AZ31B Mg alloy and AA6061-T6 Al alloy carries significant importance to combine the different material properties and corrosion resistance along with cost reduction. However, the dissimilar welding of AZ31B Mg alloy and AA6061-T6 Al alloy is very much challenging by fusion welding processes due to the formation of intermetallic compounds leading to solidification cracking. Spot welding is preferentially used in automotive sector as it is economical and faster than other welding processes. The spot welding of Al and Mg alloy is difficult by resistance spot welding (RSW) and laser beam spot welding (LBSW) due to the high thermal conductivity, lower melting point and reflectivity. So, in this investigation a solid-state friction stir spot welding (FSSW) is employed to develop the dissimilar welds of AZ31B Mg alloy and AA6061-T6 Al alloy. The FSSW parameters significantly influence the strength of welded joints. The response surface methodology (RSM) and design expert software are broadly utilized for the process parameter optimization and enhance the strength of joints. So, the main aim of this study is to optimize the FSSW parameters mainly tool rotational speed (rpm), tool plunging rate (mm/min), dwell time (s) and tool diameter ratio. The parametric mathematical model (PMM) was generated for predicting the tensile shear fracture load (TSFL) capability of AZ31B/AA6061-T6 alloy joints. Results showed that the AZ31B/AA6061-T6 joints made using tool rotational speed of 1000 rpm, plunge depth of 16 mm/min, dwell time of 5 s and tool diameter ratio of 3.0 exhibited maximum TSFL capability of 3.61 kN. The plunge rate showed a significant effect on the TSFL capability of joints followed by tool rotational speed, tool diameter ratio and dwell time.
Optimization of friction stir spot welding parameters for joining dissimilar AZ31B magnesium alloy and AA6061 aluminium alloy using response surface methodology
https://orcid.org/http://orcid.org/0000-0001-7044-1969
https://orcid.org/http://orcid.org/0000-0002-3997-5337
https://orcid.org/http://orcid.org/0000-0002-5207-0049
AZ31B magnesium (Mg) alloy and AA6061-T6 aluminium (Al) alloy are preferentially used in automotive industries due to its good mechanical properties, light weight, and corrosion resistance. The dissimilar welding of AZ31B Mg alloy and AA6061-T6 Al alloy carries significant importance to combine the different material properties and corrosion resistance along with cost reduction. However, the dissimilar welding of AZ31B Mg alloy and AA6061-T6 Al alloy is very much challenging by fusion welding processes due to the formation of intermetallic compounds leading to solidification cracking. Spot welding is preferentially used in automotive sector as it is economical and faster than other welding processes. The spot welding of Al and Mg alloy is difficult by resistance spot welding (RSW) and laser beam spot welding (LBSW) due to the high thermal conductivity, lower melting point and reflectivity. So, in this investigation a solid-state friction stir spot welding (FSSW) is employed to develop the dissimilar welds of AZ31B Mg alloy and AA6061-T6 Al alloy. The FSSW parameters significantly influence the strength of welded joints. The response surface methodology (RSM) and design expert software are broadly utilized for the process parameter optimization and enhance the strength of joints. So, the main aim of this study is to optimize the FSSW parameters mainly tool rotational speed (rpm), tool plunging rate (mm/min), dwell time (s) and tool diameter ratio. The parametric mathematical model (PMM) was generated for predicting the tensile shear fracture load (TSFL) capability of AZ31B/AA6061-T6 alloy joints. Results showed that the AZ31B/AA6061-T6 joints made using tool rotational speed of 1000 rpm, plunge depth of 16 mm/min, dwell time of 5 s and tool diameter ratio of 3.0 exhibited maximum TSFL capability of 3.61 kN. The plunge rate showed a significant effect on the TSFL capability of joints followed by tool rotational speed, tool diameter ratio and dwell time.
Optimization of friction stir spot welding parameters for joining dissimilar AZ31B magnesium alloy and AA6061 aluminium alloy using response surface methodology
https://orcid.org/http://orcid.org/0000-0001-7044-1969
https://orcid.org/http://orcid.org/0000-0002-3997-5337
https://orcid.org/http://orcid.org/0000-0002-5207-0049
AZ31B magnesium (Mg) alloy and AA6061-T6 aluminium (Al) alloy are preferentially used in automotive industries due to its good mechanical properties, light weight, and corrosion resistance. The dissimilar welding of AZ31B Mg alloy and AA6061-T6 Al alloy carries significant importance to combine the different material properties and corrosion resistance along with cost reduction. However, the dissimilar welding of AZ31B Mg alloy and AA6061-T6 Al alloy is very much challenging by fusion welding processes due to the formation of intermetallic compounds leading to solidification cracking. Spot welding is preferentially used in automotive sector as it is economical and faster than other welding processes. The spot welding of Al and Mg alloy is difficult by resistance spot welding (RSW) and laser beam spot welding (LBSW) due to the high thermal conductivity, lower melting point and reflectivity. So, in this investigation a solid-state friction stir spot welding (FSSW) is employed to develop the dissimilar welds of AZ31B Mg alloy and AA6061-T6 Al alloy. The FSSW parameters significantly influence the strength of welded joints. The response surface methodology (RSM) and design expert software are broadly utilized for the process parameter optimization and enhance the strength of joints. So, the main aim of this study is to optimize the FSSW parameters mainly tool rotational speed (rpm), tool plunging rate (mm/min), dwell time (s) and tool diameter ratio. The parametric mathematical model (PMM) was generated for predicting the tensile shear fracture load (TSFL) capability of AZ31B/AA6061-T6 alloy joints. Results showed that the AZ31B/AA6061-T6 joints made using tool rotational speed of 1000 rpm, plunge depth of 16 mm/min, dwell time of 5 s and tool diameter ratio of 3.0 exhibited maximum TSFL capability of 3.61 kN. The plunge rate showed a significant effect on the TSFL capability of joints followed by tool rotational speed, tool diameter ratio and dwell time.
Optimization of friction stir spot welding parameters for joining dissimilar AZ31B magnesium alloy and AA6061 aluminium alloy using response surface methodology
Int J Interact Des Manuf
Rajendran, C. (Autor:in) / Sonar, Tushar (Autor:in) / Ivanov, Mikhail (Autor:in) / Kumar, P. Senthil (Autor:in) / Amarnath, V. (Autor:in) / Lokanadham, R. (Autor:in)
01.01.2025
12 pages
Aufsatz (Zeitschrift)
Elektronische Ressource
Englisch
Friction stir spot welding , AZ31B magnesium alloy , AA6061-T6 aluminium alloy , Tensile shear fracture load , Response surface methodology , Analysis of variance Engineering , Materials Engineering , Engineering, general , Engineering Design , Mechanical Engineering , Computer-Aided Engineering (CAD, CAE) and Design , Electronics and Microelectronics, Instrumentation , Industrial Design
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