Abstract
This experimental work aims to devise and establish quadratic regression equations, including various input criteria of a friction stir welding (FSW) technique to predict and determine the responses during the fabrication of AZ91C Mg alloy joints. The input process parameters taken into consideration include the traversing speed of the tool, the speed of rotation of the tool, its pin profile (geometry) and the axial force. A five-level, 4 four-factor composite design (of central nature) was applied, and response surface methodology (RSM) was used to formulate quadratic regression models, to develop 3D response surface charts, and to anticipate the responses for various mechanical properties. The generated quadratic mathematical model was tested and validated using the technique of analysis of variance. Validation experimental trial results outlined in the form of scatter diagrams revealed precedented coincidence with that of the generated models. The AZ91C Mg alloy joints obtained using the tool having taper cylindrical pin geometry employed at 1045 rpm, 1.5 mm/s traversing speed, under the exertion of an axial load of 4.87 kN was found to exhibit improved mechanical properties.
Highlights
Among the lightweight category materials, alloys of magnesium, especially AZ91C Mg alloy, are employed for an ample range of aerospace, automobile, and shipbuilding sectors, given their excellent specific strength, recyclability, higher values of specific stiffness, outstanding machinability, lower density values etc. [1] and [2]
The results reveals that the peak temperature was the preeminent factor in controlling the fabricated weldment’s grain microstructure
Process parameters, either at their highest (+2) value or at their least (–2) value together with other four process parameters at their respective intermediate levels. These foresaid 31 investigational runs permit the evaluation of the quadratic equations and double-way interactive and collective impacts of these input parameters of friction stir welding (FSW) on the various responses
Summary
Among the lightweight category materials, alloys of magnesium, especially AZ91C Mg alloy, are employed for an ample range of aerospace, automobile, and shipbuilding sectors, given their excellent specific strength, recyclability, higher values of specific stiffness, outstanding machinability, lower density values etc. [1] and [2]. Recent research [15] to [23] carried out with respect to friction stir welding has demonstrated that improvement has taken place in the mechanical properties of Al alloy joints, due to the refinement of the grain structures and modifications in the microstructure of the welded regions. Alternative, better combinations of welding process parameters always exist, which can be employed, only if they can be determined In this experimental investigation, an endeavour has been made to predict the ideal and optimized combination of input parameters of FSW technique to achieve maximized mechanical properties including yield, tensile strengths and percentage of elongation, through the employment of a statistically and mathematically advanced technique: response surface methodology
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