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Research Papers

Tool Geometries Optimization for Friction Stir Welding of AA6061-T6 Aluminum Alloy T-Joint Using Taguchi Method to Improve the Mechanical Behavior

[+] Author and Article Information
Faiz F. Mustafa

Al-Khwarizmi College of Engineering,
University of Baghdad,
Baghdad 10071, Iraq
e-mail: faizalrawy@yahoo.com

Ali H. Kadhym

Al-Khwarizmi College of Engineering,
University of Baghdad,
Baghdad 10071, Iraq
e-mail: kadhumali59@yahoo.com

Hiba H. Yahya

Automated Manufacturing Department,
Al-Khwarizmi College of Engineering,
University of Baghdad,
Baghdad 10071, Iraq
e-mail: lunar_cycle86@yahoo.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received May 26, 2014; final manuscript received February 13, 2015; published online March 12, 2015. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 137(3), 031018 (Jun 01, 2015) (8 pages) Paper No: MANU-14-1295; doi: 10.1115/1.4029921 History: Received May 26, 2014; Revised February 13, 2015; Online March 12, 2015

The effect of friction stir welding (FSW) T-joints for 3 mm AA6061-T6 aluminum alloy plates on mechanical properties has been investigated in the current work by using the nine different tool shapes that were designed according to Taguchi orthogonal array (OA) without changing the process parameters (tool rotation speed, welding speed, tool tilt angle, plunge depth, and die radii). Four variable geometrical parameters (shoulder diameter (mm), pin diameter (mm), pin angle (α, deg), and groove pin shape) with three levels for each parameter have been used. The signal to noise (S/N) ratio technique was performed for analyzing results (ultimate tensile strength across the skins (UTSSkins) and ultimate tensile strength across the stringers (UTSStringers)) using the statistical software (minitabtm® 16) to establish the best optimum condition. The conformation test was also performed by fulfilling the welding process at the optimum condition to compare the theoretical and experimental results. In addition, the analysis of variance (ANOVA) technique was performed using the statistical software (design of experiments, doe pro xl) to identify the significant factors affecting on the (UTSSkins and UTSStringers).

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Figures

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Fig. 1

The explicative graphing of FSW T-joints process

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Fig. 2

Geometrical parameters for the FSW process

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Fig. 3

The required dimensions of skin and stringer

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Fig. 4

The nine manufactured tools

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Fig. 5

Milling machine and fixture parts for the (T-joints) FSW

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Fig. 6

The final welded part of T-joint

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Fig. 7

The dimensions of tensile specimen and standard tensile specimen

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Fig. 8

(a) Specimen of hoop stress test. (b) Specimen of T-pull test. (c) The clamping device for T-pull test.

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Fig. 9

(a) The percentage of contribution of the factors (A, B, C, and D) for UTSSkins. (b) The percentage of contribution of the significant factors for the UTSSkins at the (90%) confidence.

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Fig. 10

(a) The percentage of contribution of the factors (A, B, C, and D) for UTSStringers. (b) The percentage of contribution of the significant factors for the UTSStringers at the (90%) confidence.

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