Abstract

Dual phase titanium alloy is mainly used in aircraft industries due to low density, greater strength and superior thermal properties. However, titanium alloy is highly reactive to all materials and easy immersion of interstitial constituent leads to material embrittlement, so it is difficult to process and weld. So experimental investigation of friction stir welding (FSW) process is expensive. To overcome these, in the present work a finite element simulation has been developed in ABAQUS software for the FSW process to comprehend the process physics and to predict the mechanical properties of FSW component. The simulation has been carried out by changing the parameters and the performed simulation results such as stress strain plots, percentage elongation, yield and ultimate tensile strength has been verified and calibrated with experiment results. The FSW welding parameters have been optimized using Genetic algorithm to get better weld quality. The fitness function for genetic algorithm is evaluated using regression analysis. The optimized value of rotational and transverse speed to achieve maximum yield and ultimate tensile strength are 1000 rpm and 4 in./min respectively. The optimized results have also been compared with the Taguchi method.

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