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10.FSWP January2014

The document discusses optimizing friction stir welding process parameters for different joint configurations using the Taguchi method. It analyzes butt, lap and T-joints of aluminum alloy to determine the best parameter combinations for higher quality welds. Preliminary results on static strength of hybrid friction stir bonds combining welding and adhesive bonding are also presented.

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13 views2 pages

10.FSWP January2014

The document discusses optimizing friction stir welding process parameters for different joint configurations using the Taguchi method. It analyzes butt, lap and T-joints of aluminum alloy to determine the best parameter combinations for higher quality welds. Preliminary results on static strength of hybrid friction stir bonds combining welding and adhesive bonding are also presented.

Uploaded by

Anh Quang Ngo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Friction stir welding process optimization

and hybrid bonding technology

Ana C. F. Silva1, Daniel F. O. Braga2, M. A. V. de Figueiredo3, Lucas F. M. da Silva4


and P. M. G. P. Moreira5
1
Institute of Mechanical Engineering and Industrial Management (INEGI), Campos da FEUP, Rua Dr.
Roberto Frias, 400, 4200-465 Porto, Portugal; e-mail: asilva@inegi.up.pt
2
Institute of Mechanical Engineering and Industrial Management (INEGI), Campos da FEUP, Rua Dr.
Roberto Frias, 400, 4200-465 Porto, Portugal; e-mail: dbraga@inegi.up.pt
3
Faculty of Engineering Of University of Porto (FEUP), Rua Dr. Roberto Frias, s/n, 4200-465 Porto,
Portugal; e-mail: mfiguei@fe.up.pt
4
Faculty of Engineering Of University of Porto (FEUP), Rua Dr. Roberto Frias, s/n, 4200 -465 Porto,
Portugal; e-mail: lucas@fe.up.pt
5
Institute of Mechanical Engineering and Industrial Management (INEGI), Campos da FEUP, Rua Dr.
Roberto Frias, 400, 4200-465 Porto, Portugal; e-mail: pmgpm@Fe.up.pt

Abstract :
Friction stir welding (FSW) is a highly reliable joining process creating excellent opportunities for
new concepts in structural design. Optimum process parameters set are of prime importance for future
research and industrial implementation, as it will allow for consistent and sound welds. In certain
structural applications where fatigue and corrosion are prime concerns and/or lap joint configurations
are better suited, a new joining method based on FSW can be employed. This process consists of
combining friction stir welding with adhesive bonding in order to obtain a hybrid bonding technology.
In this paper, it is aimed to fill a lack in literature concerning to FSW parameters optimization for
different joint configurations. Friction stir welded butt, lap and T-joints of AA6082-T6 aluminium
alloy optimization through the Taguchi method. The process optimization was achieved and the best
parameters combination to accomplish higher quality weld joints were selected. As well as the most
influent welding parameters and their trends were identified to each joint configuration. Preliminary
results on static strength of friction stir hybrid bonds are also presented in this study.

Keywords: Friction stir welding, Taguchi, butt joints, T-joints, optimization, hybrid joining.

Friction stir welding is a solid state welding process where a special tool is inserted while in rotation
between the workpieces edges and transversed along the line of the joint. The tool generates heat by
friction and induces strong plastic deformation in the material, promoting its complex mixing across
the joint (see in Figure 1) [1]. This process was originally developed at The Welding Institute (TWI)
for aluminum alloys, but since then FSW has been gradually implemented in joints of a large number
of diferent materials, and even dissimilar joints have been produced with this technique [2].

Figure 1: Schematic diagram of FSW process [3]


Taguchi method is one of the most innovative methods for quality control that has been widely
applied for optimization of materials processing. This method is based on the statistical analysis of
data and offers a simple mean of analysis and optimization of complex systems [4, 5].
Several welds were performed following the orthogonal arrays previously defined by the Taguchi
methodology for each joint configuration. AA 6082-T6 plates of 3 mm thick were used to perform the
butt and T-joints welds and 2 mm plates thickness used in lap joints. These were welded along the
rolling direction in a modified milling machine. Several welding parameters were studied including
the rotational speed, welding speed tilt angle, probe penetration, shoulder/probe ratio and in the case
of lap joints, distance between passes in double pass welding. The joints ultimate tensile strengths
(UTS) were evaluated trough tensile tests which were then used as input data in ANOVA analyses.
The influence in UTS of welding parameters and their interactions was evaluated.
With this study it was demonstrated that Taguchi’s robust orthogonal array design method is suitable
for the optimization of FSW aluminium welding. The most influential welding parameter and/or their
interaction to each joint configuration were defined. The contribution of each parameter and their
interaction in the UTS was defined. Also, the trends of each parameter and their interactions in UTS
were evaluated. An optimal set of parameters was defined for each joint configuration analysed.
Using the parameters set for lap joints defined in the optimization study, hybrid bonds were
performed, using the commercially available adhesive Araldite A420. Tensile strength specimens
were produced and tested. Ultimate strength of these joints was compared with regular FSW lap
joints.

Acknowledgement
This work was supported by the FCT project PTDC/EME-TME/114703/2009 and FCT project
PTDC/EME-TME/117596/2010. Dr. Moreira acknowledges POPH – QREN Tipologia 4.2 –
Promotion of scientific employment funded by the ESF and MCTES.

References
[1] Moreira, P.M.G.P., M.A.V. de Figueiredo, and P.M.S.T. de Castro. Fatigue behaviour of FSW and
MIG weldments for two aluminium alloys, Theoretical and Applied Fracture Mechanics, 48(2): p.
169-177, 2007.
[2] Moreira, P.M.G.P., et al. Mechanical and metallurgical characterization of friction stir welding
joints of AA6061-T6 with AA6082-T6, Materials & Design, 30(1): p. 180-187, 2009.
[3] Silva, A. C. F., D. F. O. Braga, M. A. V. d. Figueiredo and P. M. G. P. Moreira. Friction stir
welded T-joints optimization, Materials & Design, 55(0): 120-127, 2014.
[4] Dhas, J. E. R. A Review on Optimization of Welding Process, Procedia Engineering, 38(0): 544-
554, 2012.
[5] Ross, P. J. Taguchi techniques for quality engineering : loss function, orthogonal experiments,
parameter and tolerance design. New York, McGraw-Hill, 1996.

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