تحلیل آماری و بهینه‌سازی استحکام کششی اتصال لب‌به‌لب آلیاژ آلومینیوم گرید 7075 حاصل از جوشکاری اصطکاکی اغتشاشی خشک و خیس با استفاده از روش رویه پاسخ و تابع مطلوبیت

نوع مقاله : مقاله پژوهشی

نویسندگان

1 دانشکده مهندسی مکانیک و مکاترونیک، دانشگاه صنعتی شاهرود، شاهرود، ایران

2 گروه مهندسی مکانیک، دانشکده فنی و مهندسی، دانشگاه ملایر، ملایر، ایران

چکیده

تأثیرات ناشی از سیکل‌های حرارتی در فرآیند جوشکاری اصطکاکی اغتشاشی منجر به نرم‌شدگی اتصال آلیاژهای عملیات حرارتی‌پذیر آلومینیوم می‌شود. برای رفع این محدودیت، فرآیند جوشکاری اصطکاکی اغتشاشی در زیر آب توسعه یافته است. در این پژوهش، در ابتدا با استفاده از جوشکاری اصطکاکی اغتشاشی، اتصالات لب‌به‌لب از آلیاژ آلومینیوم گرید 7075تولید شدند. بدین‌منظور، روش رویه پاسخ به عنوان روش طراحی آزمایش، انتخاب گردید و متغیرهای: سرعت دورانی ابزار، نرخ پیشروی ابزار، قطر شانه ابزار و زاویه انحراف ابزار به عنوان متغیرهای ورودی، تعیین شدند. در ادامه، تحلیل آماری پارامترهای موثر بر استحکام کششی اتصالات به انجام رسید. سپس با استفاده از جوشکاری اصطکاکی اغتشاشی در زیر آب و بر اساس مقادیر بهینه نرخ پیشروی ابزار و زاویه انحراف ابزار، اتصالات لب‌به‌لب تولید شدند. نتایج حاصل از آنالیز واریانس و تحلیل رگرسیون داده‌های حاصل از آزمون‌های تجربی، صحت و دقت معادلات رگرسیون را مورد تأیید قرار داد و نشان داد که عبارات خطی، تعاملی و سهموی از متغیرهای سرعت دورانی ابزار و قطر شانه ابزار بر استحکام کششی نهایی اتصالات تولید‌شده در زیر آب، موثر هستند. همچنین، شرایط بهینه متغیرهای ورودی فرآیند با استفاده از روش مطلوبیت، تعیین شد و با اجرای آزمون صحه‌گذاری، به تأیید رسید.

کلیدواژه‌ها

موضوعات

عنوان مقاله [English]

Statistical analysis and optimization of tensile strength of Al7075 butt joint produced by friction stir welding and submerged friction stir welding via response surface methodology and desirability approach

نویسندگان [English]

  • Mahdi Vahdati 1
  • Mahmoud Moradi 2
1 Faculty of Mechanical and Mechatronics Engineering, Shahrood University of Technology, Shahrood, Iran
2 Department of Mechanical Engineering, Malayer University, Malayer, Iran
چکیده [English]

The thermal cycles involved in friction stir welding process cause softening in the joint of heat-treatable aluminum alloys. To overcome this limitation, submerged friction stir welding process has been developed. In this study, firstly, the butt joints were produced from Al7075-T6 alloy using friction stir welding process. To this end, the response surface methodology was selected as the experiment design technique. So, the factors such as tool rotational speed, tool feed rate, tool shoulder diameter, and tool tilt angle were identified as the input variables. Then, a statistical analysis of variables affecting the tensile strength of joints was performed. Afterward, the butt joints were produced using submerged friction stir welding process based on the optimal values of tool feed rate and tool tilt angle. The obtained results from analysis of variance and regression analysis of experimental data confirmed the accuracy of regression equations. Furthermore, it is shown that the linear, interactional and quadratic terms of the tool rotational speed and tool shoulder diameter are effective on the ultimate tensile strength of the underwater welded joints. Also, the optimal condition of input variables was determined using the desirability method. In addition, the optimal condition has been confirmed by implementing the verification test.

کلیدواژه‌ها [English]

  • Statistical analysis
  • Optimization
  • Tensile strength
  • Friction stir welding
  • Response surface methodology

مراجع

[1] R. Tamasgavabari, A.R. Ebrahimi, S.M. Abbasi, A.R. Yazdipour, Effect of harmonic vibration during gas metal arc welding of AA-5083 aluminum alloy on the formation and distribution of intermetallic compounds, Journal of Manufacturing Processes, 49 (2020) 413-422.
[2] B. Qin, F.C. Yin, C.Z. Zeng, J.C. Xie, J. Shen, Microstructure and mechanical properties of TIG/A-TIG welded AZ61/ZK60 magnesium alloy joints, Transactions of Nonferrous Metals Society of China, 29 (9) (2019) 1864-1872.
[3] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P.T. Smith, C.J. Dawes, Friction stir butt welding, Int. Patent No. PCT/GB92/02203 (1991).
[4] M. Guerra, C. Schmidt, L.C. Mcclure, L.E. Murr, A.C. Nunes, Flow patterns during friction stir welding, Materials Characterization, 49 (2003) 95-101.
[5] C.G. Rhodes, M.W. Mahoney, W.H. Bingel, R.A. Spurling, C.C. Bampton, Effects of friction stir welding on microstructure of 7075 aluminum, Scripta Materialia, 36 (1) (1997) 69-75.
[6] J. Zhao, F. Jiang, H.G. Jian, K. Wen, L. Jiang, X.B. Chen, Comparative investigation of tungsten inert gas and friction stir welding characteristics of Al−Mg−Sc alloy plates, Materials and Design, 31 (2010) 306-311.
[7] R.J. Steel, S.M. Packer, R.D. Fleck, S. Sanderson, C. Tucker, Advances in FSW and new applications, Editor: Fujii H, Proceedings of the 1st International Joint Symposium on Joining and Welding, Woodhead Publishing, (2013) 125-127.
[8] W.M. Thomas, E.D. Nicholas, Friction stir welding for the transportation industries, Materials and Design, 18 (1997) 269-273.
[9] A.N. Siddiquee, S. Pandey, Experimental investigation on deformation and wear of WC tool during friction stir welding (FSW) of stainless steel, International Journal of Advanced Manufacturing Technology, 73 (2014) 479-486.
[10] R.A. Gite, P.K. Loharkar, R. Shimpi, Friction stir welding parameters and application: A review, Materials Today: Proceedings, 19 (2) (2019) 361-365.
[11] J.H. Cho, S.H. Han, C.G. Lee, Cooling effect on microstructure and mechanical properties during friction stir welding of Al−Mg−Si aluminum alloys, Materials Letters, 180 (2016) 157-161.
[12] L. Fratini, G. Buffa, R. Shivpuri, In-process heat treatments to improve FS-welded butt joints, International Journal of Advanced Manufacturing Technology, 43 (2009) 664.
[13] D. Sakurada, K. Katoh, H. Tokisue, Underwater friction welding of 6061 aluminum alloy, Journal of Japan Institute of Light Metals, 52 (1) (2002) 2-6.
[14] H.A. Derazkola, F. Khodabakhshi, Underwater submerged dissimilar friction-stir welding of AA5083 aluminum alloy and A441 AISI steel, International Journal of Advanced Manufacturing Technology, 102 (2019) 4383-4395.
[15] R. Rouzbehani, A.H. Kokabi, H. Sabet, M. Paidar, O.O. Ojo, Metallurgical and mechanical properties of underwater friction stir welds of Al7075 aluminum alloy, Journal of Materials Processing Technology, 262 (2018) 239-256.
[16] M.A. Mofid, A. Abdollah-Zadeh, F.M. Ghaini, C.H. Gur, Submerged friction-stir welding (SFSW) underwater and under liquid nitrogen: An improved method to join Al alloys to Mg alloys, Metallurgical and Materials Transactions A, 43 (2012) 5106-5114.
[17] S.S. Sabari, S. Malarvizhi, V. Balasubramanian, G.M. Reddy, Experimental and numerical investigation on under-water friction stir welding of armour grade AA2519-T87 aluminium alloy, Defence Technology, 12 (2016) 324-333.
[18] H.J. Zhang, H.J. Liu, L. Yu, Microstructure and mechanical properties as a function of rotation speed in underwater friction stir welded aluminum alloy joints, Materials and Design, 32 (2011) 4402-4407.
[19] T.W. Nelson, R.J. Steel, W.J. Arbegast, In situ thermal studies and post-weld mechanical properties of friction stir welds, Science and Technology of Welding and Joining, 8 (4) (2003) 283-288.
[20] W.F. Xua, J.H. Liu, D.L. Chen, G.H. Luan, J.S. Yao, Improvements of strength and ductility in aluminum alloy joints via rapid cooling during friction stir welding, Materials Science and Engineering A, 548 (2012) 89-98.
[21] H.J. Liu, H.J. Zhang, Y.X. Huang, Y. Lei, Mechanical properties of underwater friction stir welded 2219 aluminum alloy, Transactions of Nonferrous Metals Society of China, 20 (2010) 1387-1391.
[22] Q. Wang, Z. Zhao, Y. Zhao, K. Yan, H. Zhang, The adjustment strategy of welding parameters for spray formed 7055 aluminum alloy underwater friction stir welding joint, Materials and Design, 88 (2015) 1366-1376.
[23] H.J. Liu, H.J. Zhang, L. Yu, Effect of welding speed on microstructures and mechanical properties of underwater friction stir welded 2219 aluminum alloy, Materials and Design, 32 (3) (2011) 1548-1553.
[24] H. Zhang, H. Liu, Mathematical model and optimization for underwater friction stir welding of a heat-treatable aluminum alloy, Materials and Design, 45 (2013) 206-211.
[25] H.J. Zhang, H.J. Liu, L. Yu, Effect of water cooling on the performances of friction stir welding heat-affected zone, Journal of Materials Engineering and Performance, 21 (7) (2012) 1182-1187.
[26] Q. Wang, Y. Zhao, K. Yan, S. Lu, Corrosion behaviour of spray formed 7055 aluminum alloy joint welded by underwater friction stir welding, Materials and Design, 68 (2015) 97-103.
[27] E.E. Kishta, B. Darras, Experimental investigation of underwater friction-stir welding of 5083 marine-grade aluminum alloy, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 230 (3) (2014) 458-465.
[28] S.S. Sabari, S. Malarvizhi, V. Balasubramanian, Influences of tool traverse speed on tensile properties of air cooled and water cooled friction stir welded AA2519-T87 aluminium alloy joints, Journal of Materials Processing Technology, 237 (2016) 286-300.
[29] R.H. Myers, D.C. Montgomery, C.M. Anderson-Cook, Response surface methodology: process and product optimization using designed experiments, John Wiley & Sons, ISBN 978-1-118 91601-8 (2016).
[30] M. Vahdati, M. Moradi, Statistical analysis and optimization of the yield strength and hardness of surface composite Al7075/Al2O3 produced by FSP via RSM and desirability approach, Iranian Journal of Materials Forming, 7 (1) (2020) 32-45.
[31] M. Vahdati, M. Moradi, M. Shamsborhan, Modeling and Optimization of the Yield Strength and Tensile Strength of Al7075 Butt Joint Produced by FSW and SFSW Using RSM and Desirability Function Method, Transactions of the Indian Institute of Metals, doi: 10.1007/s12666-020-02075-8 (2020).
[32] Design Expert software, version 11, http://www.statease.com.
[33] A. Esmaeili, M.H. Shaeri, M. Talafi Noghani, A. Razaghian, Fatigue behavior of AA7075 aluminium alloy severely deformed by equal channel angular pressing, Journal of Alloys and Compounds, 757 (2018) 324-332.
[34] J.F. Li, Z.W. Peng, C.X. Li, Z.Q. Jia, W.J. Chen, Z.Q. Zheng, Mechanical properties, corrosion behaviors and microstructures of 7075 aluminium alloy with various aging treatments, Transactions of Nonferrous Metals Society of China, 18 (4) (2008) 755-762.
[35] A. Heinz, A. Haszler, C. Keidel, S. Moldenhauer, R. Benedictus, W.S. Miller, Recent development in aluminium alloys for aerospace applications, Materials Science and Engineering: A, 280 (1) (2000) 102-107.
[36] J.C. Williams, E.A. Starke, Progress in structural materials for aerospace systems, Acta Materialia, 51 (19) (2003) 5775-5799.
[37] N. Mendes, P. Neto, A. Loureiro, A.P. Moreira, Machines and control systems for friction stir welding: A review, Materials & Design, 90 (2016) 256-265.
[38] AMSH6088: Heat Treatment of Aluminum Alloys, SAE International, https://www.sae.org.
[39] http://www.matweb.com
[40] D.C. Montgomery, Design and analysis of experiments, John Wiley & Sons, ISBN 978-1-119-11347-8 (2017).
 
 
نشریه مهندسی مکانیک امیرکبیر
دوره 53، شماره 4 (Special Issue)
تیر 1400
صفحه 2719-2734

فایل ها

هم رسانی

ارجاع به این مقاله

آمار