Abstract
In this study, we present a new algorithm for finding the optimal friction stir welding parameters to maximize the tensile strength of a butt joint made of the semisolid material (SSM) ADC 12 aluminum. The welding parameters were rotational speed, welding speed, tool tilt, tool pin profile, and rotational direction. The method presented is a variable neighborhood strategy adaptive search (VaNSAS) approach. The process of finding the optimal friction stir welding parameters comprises five steps: (1) identifying the type and range of friction stir parameters using a literature survey; (2) performing experiments according to (1); (3) constructing a regression model using the response surface method optimizer (RSM optimizer); (4) using VaNSAS to find the optimal parameters for the model obtained from (3); and (5) confirming the results from (4) using the parameter levels obtained from (4) to perform real experiments. The computational results revealed that the tensile strength generated from VaNSAS was 3.67% higher than the tensile strength obtained from the RSM optimizer parameters. The optimal parameters obtained from VaNSAS were a rotation speed of 2200 rpm, a welding speed of 108.34 mm/min, a tool tilt of 1.23 Deg, a tool pin profile of a hexagon, and a rotational direction of clockwise.
Highlights
Published: 11 October 2021Aluminum alloys are important for building components in various industries that require low-weight and high-strength materials, such as the automotive, marine, and aviation industries
We aimed to identify the optimal parameters of Friction stir welding (FSW) for producing the (a) TMAZ-RS, (b) TMAZ-AS, (c) Top-SZ, (d) Middle-SZ, (e) Bottom-SZ, (f) Side-SZ
D-optimal approach was used for the experimental design, and the variable neighborhood strategy adaptive search (VaNSAS) algorithm method was used for optimal parameter prediction
Summary
Aluminum alloys are important for building components in various industries that require low-weight and high-strength materials, such as the automotive, marine, and aviation industries. These industries use aluminum alloys and cast aluminum [1] due to their strength, weldability, machinability, corrosion resistance, and formability [2,3]. The fusion welding process, which uses a high temperature for melting and welding, is difficult with aluminum materials due to problems associated with the thermal expansion coefficient and the low melting point. The friction stir welding process produced a low melting point and good material mixing using a stirred tool [7,8]. Friction stir welding (FSW) does not melt and recast but utilizes plastic deformation at the welding location from frictional heat between the tool and the material
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