e-ISSN (O): 2348-4470

Scientific Journal of Impact Factor (SJIF): 4.72

p-ISSN (P): 2348-6406

International Journal of Advance Engineering and Research

Development
Volume 4, Issue 2, February -2017

Optimization of process parameters for friction stir welded aluminium alloy

AA7075 using full factorial method
1
Mr. Jignesh J. Patel, 2Dr. Mohammad Israr
1
PhD Scholar, RAI University- Ahmedabad ,
2
Principal, Dungarpur College of Engineering and Technology, Dungarpur- Rajasthan.

ABSTRACT: Friction stir welding is a recent emerging solid state joining technique used to join high strength aluminium
alloy. This present work focused to evaluate the effect of process parameters such as tool rotational speed, welding speed
and tool tilt angle on flow stress and yield strength of friction stir welded AA7075 joints. The modeling and simulation has
been carried out by using Hyper Works 14.0 simulation software. The optimum process parameters were determined by the
Taguchi full factorial parametric design approach.

1.0 INTRODUCTION

Friction Stir Welding (FSW) is a solidstate joining technique invented and patented by The Welding Institute (TWI) in 1991
for butt and lap welding of ferrous and nonferrous metals and plastics [1]. Since its invention, the process has been
continually improved upon as its scope of application becomes expanded. FSW is a continuous process that involves
plunging a portion of a specially shaped rotating tool between the abutting faces of a joint. The relative motion between the
tool and the substrate generates frictional heat that creates a plasticized region around the immersed portion of the tool. In
addition, the shoulder prevents the plasticized material from being expelled from the weld, therefore, the tool is moved
relatively along the joint line, forcing the plasticized material to coalesce behind the tool to form a solidphase joint [1]. The
inserted picture also depicts the tool shoulder and the tool pin. The tool pin is sometimes referred to as the probe. The
advancing side is on the right, where the tool rotation direction is the same as the tool travel direction (opposite the direction
of metal flow), while the retreating side is on the left, where the tool rotation is opposite to the tool travel direction (parallel
to the direction of the metal flow). The tool serves three primary functions; the heating of the work piece, the movement of
material to produce the joint, and the containment of the hot metal beneath the tool shoulder [1]. The heat generated during
the FSW process is often assumed to occur predominantly under the shoulder; due to its greater surface and to be equal to the
power required to overcome the contact forces between the tool and the work piece [3]. To an extent, the heat input into the
welds increases as the shoulder diameter increases [4]. The three different shoulder diameters used in this research study were
chosen to vary the heat input into the welds while varying the process parameter settings. The benefits of FSW process as a
technology include: low distortion, greater weld strength compared to the fusion welding process, little or no porosity, no
filler metals, no solidification cracking, no welding fumes or gases, improved corrosion resistance, and lower cost in
production applications. Because of the many demonstrated advantages of FSW over the fusion welding techniques, the
commercialization of FSW is progressing at a rapid pace [5]. FSW is considered to be the most significant development in
metal joining techniques in decades; and it is, in addition, a green technology due to its energy efficiency, environmental
friendliness and versatility. When compared to the conventional welding methods, FSW consumes considerably less energy
and no harmful emissions are created during the welding process [6]. Different microstructural zones exist after FSW, this
include: the Heat Affected Zone (HAZ) which is a region that lies closer to the parent materials, the materials have
experienced a thermal cycle that has modified the microstructure and or the mechanical properties. The Thermo Mechanically
Affected Zone (TMAZ) is a zone where the FSW tool has plastically deformed the material while the Stir Zone (SZ) also
referred to as the Weld Nugget (WN) is a fully recrystallized region; it refers to the zone previously occupied by the tool pin.
This microstructural characterization is credited to P. L. Threading [7]. From the reported literature, it is observed that
influence of AA 6061-2014 alloys on mechanical properties was studied. Hence the objective of present investigation is to
study the influence of process parameters on mechanical properties of AA 6061-2014 alloys fabricated via FSW and obtain
the optimum combinations using full factorial method were adopted to analyze the effect of each processing parameters (i.e
Tool tilt angle, welding speed and tool rotation speed) for optimum flow stress and yield strength.

2.0 EXPERIMENTAL PROCEDURE

In this work AA7075 with dimension of 300 mm 100 mm 6mm plates with chemical composition of the AA7075 is
shown in Table 1were selected to perform virtual FSW experiment using Hyper Works 14.0. The tool geometry was selected
with cylindrical pin having a shoulder diameter (D=17mm), shoulder length (L=70mm), pin diameter (d=6mm) and pin
length (l=5.4mm). Physical and thermal properties of AA 7075 are shown in Table 2. The parameters identified for

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 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

investigation are tool tilt angle, welding speed, tool rotation speed. The selected process parameter and their levels are shown
in table 3.
.
Table 1. Chemical composition of AA7075
Element Mg Mn Zn Fe Cu Si Cu Al
Wt% 2.1 0.12 5.1 0.35 1.2 0.58 1.2 Bal

Table 2. Physical & Thermal Properties of AA7075

Property Values
Density 2810 Kg/m3
Melting Point 635C
Modulus of Elasticity 40 GPa
Poisons Ratio 0.35
Thermal Conductivity 173 W/m-K
Specific Heat Capacity 960 J/Kg-K

Table 3 Process parameter and their levels.

Symbol Welding Parameter Level 1 Level 2 Level 3
TA Tilt Angle 0 1 2
WS Welding speed (mm/sec) 1.67 2.5 4.16
TS Tool rotation speed(rpm) 600 800 1000

3.0 FINITE ELEMENT MODELING AND ANALYSIS OF FRICTION STIR WELDING PROCESS

Altair Hyper Works 14.0 simulation tool is used for simulation and finite element analysis of friction stir welding process.
This software has a thermal conduction capability and can be used for a 3-dimensional, steady-state or transient thermal
analysis. Transient finite element analysis is performed considering steady state heat source. The finite element model was
developed for simulation of friction stir welding. The FSW parameters considered by the simulation suit are pin diameter, pin
height, pin rpm, pin tilt, translational speed, shoulder diameter and height. It is assumed that 90% of the work is converted
into energy. The developed finite element model has several components with their defined name, no. of elements and ID
range. Hyper Works provides an efficient interface for development of finite element model and analyzing friction stir
welding with the HyperXtrude Solver. The initial temperature of the work piece is assumed equal to the ambient temperature
(293K). Convections coefficient of 30 W/m2K is applied at the top and side surfaces of the work piece. Since the value of
conductive coefficient between the work piece and the backing plate is unknown, convective coefficient of 300 W/m 2K can
be applied to the bottom surface of the work piece. The above conditions are adopted from Colegrove [13].

Fig.1 Finite element model of friction stir welding process showing different
displayed components such as tool, butt joint, HAZ, left plate and right plate

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 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

4.0 RESULT AND DISCUSSIONS

Table 4 shows the selected design matrix based on full factorial L27 orthogonal array consisting of 27 sets of coded conditions
and the experimental results for the responses of flow stress and yield strength. All these data have been utilized for analysis
and evaluation of optimal parameter combination required to achieve desired quality weld within the experimental domain.

Table 4: Orthogonal array L27 of the experimental runs and results

Run No. Tilt Angle Welding Speed Tool rotation Flow stress Yield stress
(Degree) (mm/s) Speed (rpm) (Mpa) (Mpa)

1 0 1.67 600 358.7 87.07

2 0 1.67 800 356.2 85.03
3 0 1.67 1000 354.4 83.2
4 0 2.5 600 367.1 92.72
5 0 2.5 800 364.2 91.26
6 0 2.5 1000 362.03 89.97
7 0 4.16 600 374.7 92.55
8 0 4.16 800 372.4 94.22
9 0 4.16 1000 495.5 101.2
10 1 1.67 600 367.2 81.58
11 1 1.67 800 364.4 79.68
12 1 1.67 1000 362.2 77.54
13 1 2.5 600 377.7 86.21
14 1 2.5 800 375.1 84.11
15 1 2.5 1000 373.02 82.7
16 1 4.16 600 386.5 90.21
17 1 4.16 800 384.9 90.04
18 1 4.16 1000 383.5 89.46
19 2 1.67 600 367 80.19
20 2 1.67 800 364.2 77.74
21 2 1.67 1000 362 75.8
22 2 2.5 600 377.5 84.57
23 2 2.5 800 374.9 81.98
24 2 2.5 1000 372.7 80.88
25 2 4.16 600 386.4 88.59
26 2 4.16 800 384.8 87.29
27 2 4.16 1000 383.4 85.89

4.1 ANALYSIS OF VARIANCE

Analysis of variance (ANOVA) test was performed to identify the process parameters that are statistically significant. The
purpose of the ANOVA test is to investigate the significance of the process parameters which affect the flow stress and yield
strength of FSW joints. The ANOVA results for flow stress and yield strength of means are given in Table 5 and 6. In
addition, the F-test named after Fisher can also be used to determine which process has a significant effect on flow stress and
yield stress. Usually, the change of the process parameter has a significant effect on the quality characteristics, when F is
large (Table 5 and 6). The results of ANOVA indicate that the considered process parameters are highly significant factors
affecting the flow stress and yield strength of FSW joints in the order of rotational speed, welding speed and tool tilt angle. It
is observed from the data welding speed has significance effect on both flow stress and yield strength. Accuracy of model

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 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

was tested by using ANOVA. All term including TA, WS and TS were found to be significant at 95% confidence interval.
The determination coefficient R2 (0.9161) is also high, which indicates high significance of model.

Table: 5 Analysis of Variance for Flow stress (Mpa)

Source DF Seq SS Adj SS Adj MS F P
TA 2 73.7 73.7 36.9 0.07 0.094
WS 2 5127.2 5127.2 2563.6 4.55 0.024
TS 2 720.3 720.3 360.1 0.64 0.053
Error 20 11276.9 11276.9 563.8
Total 26 17198.1
S = 23.7454 R-Sq = 34.43% R-Sq(adj) = 14.76%

Table 6: Analysis of Variance for yield stress (Mpa).

Source DF Seq SS Adj SS Adj MS F P
TA 2 332.09 332.09 166.04 44.45 0.000
WS 2 466.39 466.39 233.19 62.42 0.000
TS 2 17.23 17.23 8.61 2.31 0.013
Error 20 74.72 74.72 3.74
Total 26 890.42 890.42
S = 1.93285 R-Sq = 91.61% R-Sq(adj) = 89.09%
DF-Degrees of freedom, Seq SS-Sequential sum of squares, Adj SS-Adjusted
Sum of square, Adj MS-Adjusted mean square, F-Fisher ratio, P-probability
that exceeds the 95 % confidence level

4.2. OPTIMIZING THE YIELD STRENGTH PROPERTIES

Analyzing data means and interaction plot for flow stress and yield strength of various process parameters, it is observed that
a larger means corresponds to better quality characteristics. Therefore, optimal level of process parameter is the level of
highest means. Mean for flow stress and yield strength was at maximum when rotational speed 600 rpm, welding speed
4.16mm/s and tool tilt angle is 0 degree, which is shown in figure 2 to figure 7.

Fig. 2 Response plot of data means for flow stress

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Fig. 3 Interaction plot for flow stress

Fig. 4 Residual plots for Flow stress

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Fig. 5 Response plot for data means for yield stress

Fig. 6 Interaction plot for Yield stress

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Fig. 7 Residual plots for Flow stress

5.0 CONCLUSION

Yield strength of Al alloy AA7075 has been evaluated under different processing parameters using full factorial experimental
design.

The Analysis of Variance for the flow stress result concludes that the welding speed is the most significant
parameter followed by tool rotation speed and tilt angle.
The analysis of variance for the yield strength result concludes that the welding speed is the most significant
parameter followed by tilt angle and tool rotation speed.
Optimum condition from main effect plot for mean and interaction plot to get good yield strength is Tool rotational
speed 600 rpm, welding speed 4.16mm/s and tool tilt angle 0 degree.

6.0 REFERENCES

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joint integrity. D.Tech dissertation, Nelson Mandela Metropolitan University, Port Elizabeth, South Africa. 2007.
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Aluminium, Volume 2 Alloy Production and Materials Manufacturing. New York, Marcel Dekker; p. 579-700,
2003.

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Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

6. Nandan R., DebRoy T. and Bhadeshia H. K. D. H, Recent advances in friction stir welding- Process, weldment
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