Abstract
This paper presents a multi-objective optimization method for optimizing the process parameters during friction welding of dissimilar metals. The proposed method combines the response surface methodology (RSM) with an a genetic algorithm (GA) method. Ultimate tensile strength (UTS), flash diameter and the heat affected zone (HAZ) width of friction welded nodular cast iron with low carbon steel joints were investigated considering the following process parameters: friction pressure (FP), friction time (FT) and upsetting pressure (UP). Mathematical models were developed and the responses were adequately predicted. Direct and interaction effects of process parameters on responses were studied by plotting graphs. In the case of UTS, FT has high significance followed by: FP and UP. Friction time has high significance on the flash diameter of nodular cast iron followed by UP and FP. However in the case of the low carbon steel flash diameter, UP has high significance followed by FT and FP. In the case of the HAZ width for nodular cast iron and low carbon steel side, friction time has high significance followed by UP and FT. Multiobjective optimization for maximizing the tensile strength and minimizing the flash diameter and the HAZ width was carried out using mathematical model.
Highlights
Friction rotary welding (FRW) is a method of joining materials which can be welded with difficulty [1]
Friction pressure and friction time have a positive effect on tensile strength
Initially the tensile strength decreases as friction time increase from 40 to 60s, reaches a minimum and increases
Summary
Friction rotary welding (FRW) is a method of joining materials which can be welded with difficulty [1]. The combined effects of process parameters on multi responses like tensile strength, flash diameter and the HAZ width in ductile iron with low carbon steel joints are hitherto not reported. Other materials such as stainless steel, aluminium alloys, magnesium or titanium alloys were considered by many researchers. The first aim is to employ RSM to develop empirical relationships relating the friction welding input parameters (friction pressure, friction time and upsetting pressure and five output responses (i.e. tensile strength, flash diameter for ductile iron and low carbon steel and the ductile iron and steel HAZ width). The second aim is to find the Pareto-optimal parameters welding combination that would maximize both the tensile strength and minimize the flashes and the HAZ width for friction welding joints
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