Abstract
Friction stir welding (FSW) is a well-established welding technique, which allows joining abutting surfaces by generating heating through a rotating and translating tool specifically shaped. Differently from the conventional techniques, continuous welding processes can be executed by FSW, thus supporting the economy of scales objectives. This paper deals with the selection of the optimal process parameters for the FSW of the AA6082 aluminum alloy. Three welding parameters, namely tool plunging, rotational speed and welding speed, have been handled as independent variables for developing two mathematical models by means of a non-linear regression-based approach, with the aim of predicting both ultimate tensile strength and ultimate elongation of the welded joints. A set of additional experimental tests has been used to validate the mentioned metamodels and finally three different metaheuristic algorithms have been implemented for selecting the best process parameters able to maximize the aforementioned mechanical properties. A comparison analysis based on further experimental tests confirmed the accuracy of the predicting metamodels and the quality of solutions yielded by the proposed optimization approaches.
Highlights
IntroductionCommon defects of the conventional welding processes, such as solidification cracking, oxidation, distortion and porosity, do not occur in the Friction stir welding (FSW) applications [2,7]
Regardless of the process parameters investigated in the present work, fracture occurs in the heat affected zone, as shown in Figure 6 in which a typical fractured tension tested FSWed sample can be observed
The optimization of process parameters concerning with the friction welding process of AA6082-T6 aluminum alloy was carried out
Summary
Common defects of the conventional welding processes, such as solidification cracking, oxidation, distortion and porosity, do not occur in the FSW applications [2,7]. Several parameters, such as tool rotational speed, welding speed, axial force, tool pin shape, tool plunging, dwelling time, etc., can affect the mechanical properties of friction stir welded joints. Simoncini and Forcellese [8] studied the effect of the ratio between rotational and welding speeds on the ultimate tensile strength (UTS) and ultimate elongation (UE)
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