Abstract
This research presents a novel algorithm for finding the most promising parameters of friction stir welding to maximize the ultimate tensile strength (UTS) and maximum bending strength (MBS) of a butt joint made of the semi-solid material (SSM) ADC12 aluminum. The relevant welding parameters are rotational speed, welding speed, tool tilt, tool pin profile, and rotation. We used the multi-objective variable neighborhood strategy adaptive search (MOVaNSAS) to find the optimal parameters. We employed the D-optimal to find the regression model to predict for both objectives subjected to the given range of parameters. Afterward, we used MOVaNSAS to find the Pareto front of the objective functions, and TOPSIS to find the most promising set of parameters. The computational results show that the UTS and MBS of MOVaNSAS generate a 2.13% to 10.27% better solution than those of the genetic algorithm (GA), differential evolution algorithm (DE), and D-optimal solution. The optimal parameters obtained from MOVaNSAS were a rotation speed of 1469.44 rpm, a welding speed of 80.35 mm/min, a tool tilt of 1.01°, a cylindrical tool pin profile, and a clockwise rotational direction.
Highlights
Cast aluminum has been used in innovative creations such as auto engines, turbine engines, etc., because it has good mechanical properties and easy fabrication
semi-solid material (SSM) aluminum was generated to compensate for the problems of cast aluminum because SSM aluminum is fabricated by a process that controls the different gains and defects within the structure
The computational results are divided into three parts: the result from the D-optimal experimental design, the results for the proposed problem using MOVaNSAS, and other compared methods
Summary
Cast aluminum has been used in innovative creations such as auto engines, turbine engines, etc., because it has good mechanical properties and easy fabrication. The problems with cast aluminum are defects in the structure such as porosity, cracking, and different gains that are difficult to control when cooling down after the casting process. Cast aluminum use has been reduced in auto engines and turbine engines. SSM (semi-solid material) aluminum was generated to compensate for the problems of cast aluminum because SSM aluminum is fabricated by a process that controls the different gains and defects within the structure. Fusion welding has been the conventional way of metal welding, but it is a difficult process for aluminum welding. The welded seam temperature is reduced rapidly by ambient air that affects welded seam through cracking, porosity, distortion, and different gains [1,2,3,4]
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