QUALITATIVE AND QUANTITATIVE ANALYSIS OF FRICTION STIR WELDING OF 6111-T4 ALLOY JOINT WITH PREHEATIN

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 10, Issue 2, Apr 2020, 115–126 © TJPRC Pvt. Ltd.

QUALITATIVE AND QUANTITATIVE ANALYSIS OF FRICTION STIR WELDING OF 6111-T4 ALLOY JOINT WITH PREHEATING NITIN B BORKAR1 & Dr. S S DESHMUKH2 1

Research Scholar Department of Mechanical Engineering, SSGMCE Shegaon, SGBA University, Maharashtra, India 2

Professor, Department of Mechanical Engineering, PRMITR Badnera, SGBA University, Maharashtra, India

ABSTRACT The rising industrial requirement for lighter, multi-material components supports the development of new joining processes. Friction Stir Welding (FSW) is one process which has the fast development in several industries. The high strength AA6111-T4 aluminum alloy is commonly used in the aerospace components due to its special mechanical properties like lightweight and high strength. This alloy cannot be welded by fusion welding techniques due to solidification cracking which severely degrade the mechanical properties of the joint. In contrast, through Friction Stir Welding (FSW) process solidification relate defects can be eliminated. An investigation includes external heat addition through preheating the metal before weld. This preheating temperature effects on microstructure and overall mechanical properties of the goof quality joints were investigated by using qualitative and quantitative approaches. Factorial design, this study, the following conclusions are derived. Sufficient heat input should be given to obtain defect free and quality joint. The results showed that preheating the base metal to 100 -150°C prior to welding improved the tensile strength and joint efficiency compared to the joints made without preheating.

KEYWORDS: ANOVA, Preheating, Factorial Design, FSW & Aluminium Alloy

Original Article

ANOVA and empirical regression models were used to analyze samples without preheating and with preheating. From

Received: Mar 20, 2020; Accepted: Apr 10, 2020; Published: Apr 25, 2020; Paper Id.: IJMPERDJUN202011

1. INTRODUCTION Friction Stir Welding (FSW) is a solid state welding process which was developed by TWI in the United Kingdom two and half decades before. In FSW, the non consumable rotating tool normally plunged at the interface of base metals. The material get plasticized at the front of the tool is extruded and forged at the back end of the tool when tool moved forward, thus the weld joint is produced [3-5]. In commercial point of view, productivity of friction stir welded component is a challenging task. It means that increasing welding speed beyond optimal value is not possible. As the welding speed increases the heat input reduces and the corresponding heating area around the tool also reduces which leads to poor quality weld joint [4]. In addition higher welding speed also leads to tool failure, for this reason many researchers have replaced costly tools [9]. Few authors have improved welding speed of friction stir welding by preheating the base metal with external heat source [5-9]. In normal friction, stir weld preheating of base metal is achieved by increasing the dwell time period in the plunging stage. Increasing dwell time period does not offer significant temperature improvement in weld [5]. For preheating external heating can be used, it is recognized through analytical model that external heat can enhance quality of the weld and also increase the welding speed [6]. Preheating of base metal of the weld improved the strength and Vickers hardness of the weld joint [7]. External heating provide at the bottom of the weld plate also improved the strength of the weld [8].

Different methods of preheating are employed, Yaduwanshi, et al. used plasma for preheating in friction stir

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welding to weld aluminum alloy [12], Lotfi et al. designed a preheating setup and optimized its process parameters [13], and Sun et al. applied gas welding torch for preheating in friction stir spot welding of carbon steel weld [9]. Form these literatures, it can be suggested that preheating with gas weld torch is the simple and effective approach among these preheating techniques. This simple gas weld torch heating was implemented in this research. Preheating can improve the welding speed but it reduces the frictional stress of base metal which results in less friction heat generation [5]. Hence, an effort has made to examine the relations between preheating temperature and mechanical characteristics of friction stir welded AA 6111-T4 aluminum alloy joint. Experimentation was concentrated on improvement of tensile strength, finding of optimal preheating temperature and analysis the changes in microstructure under preheated condition.

2. EXPERIMENTAL PROCEDURES The rolled aluminum alloy similar 6111-T4 plate of thickness 5mm was used as parent metal for this investigation.

Chemical composition and mechanical properties of this base metal are listed in Table 1. The plate was reduced into rectangles of dimension 150 mm length and 70 mm width. These machined plates were welded in normal to the rolling direction using computer numerical controlled VMC -FSW machine (22 kW, 3000 rpm, 6 ton).

Table 1: Properties of Aluminium Alloy and Tool Material Chemical Composition of AA 6111 T 4 Perpendicular to the Rolling Direction Alloy Si Fe Cu Mn Mg Cr Ti V Al 6111-T4 1.1 0.4 0.9 0.45 1.0 0.1 0.1 BM TS- 230-290 Mpa Elongation (%) M.P. -6000C Hardness-70 Hrc TOOL-AISI 1020 (Oil Hardened) T.S.- 475 Mpa HRc -95-110 M.P.-1500 0C A cylindrical pin with and without threaded profiled tool made of water hardened medium carbon steel was used to fabricate all the weld joints on VMC workbench, as shown in figure 1a.1b.

Figure 1: a. Image of FSW Experimental Set up- Bench Vice b. Illustrated Image of AISI 1020 FSW CLP Tool

3. DESIGN OF EXPERIMENT The process parameter are selected from usual set of process parameters like tool rotational speed, tool travel speed, axial pressure, weld angle and shoulder diameter. The used parameters to fabricate the normal weld are tool rotational speed of 1000 rpm-1100 rpm, welding speed of 10-15 mm/min and shoulder diameter 15-20 mm with constant axial pressure 7 KN for two level and three factor design by using Minitab 16 statistical software as referred in “Table 2”. To study the effect of preheating temperature, the above process parameters were kept constant and preheating temperature alone was varied as 100 °C, 150 °C. With these temperatures and two different tool profiles, many samples were fabricated. These fabricated weld joints are shown in “Figure. 1”. Here, preheating of base metal was achieved by induction coiled with copper cover plate of 600 watt. Tool followed preheating set to allow the base metal to heat.

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Table 2: Factorial Design for Process Parameters Trials RS( RPM) TS (mm/min) SD (mm) 1 1000 15 15 2 1000 15 20 3 1100 15 15 4 1100 10 20 5 1000 10 20 6 1100 10 15 7 1000 10 15 8 1100 15 20 During the welding, peak temperature of each joint was measured near to the stir zone. The joint fabricated without preheating and with preheating was referred as PR, WPRHT and PRHT joint respectively. These welded joints were cut and machined to obtain unnothched tensile specimens with dimension as specified in ASTM E8 M-04 guidelines [14]. The dimensions of the tensile specimen are shown in Figure 3. The tensile test was carried out in 100 kN, servo controlled universal testing machine (Model: UNITEK, INDIA). The metallographic samples were prepared and etched with Keller’s reagent to expose the microstructure in different zones of weld nugget. The microstructure of the weld samples were examined using optical metallurgical microscope. The hardness values were measured along the weld centerline by using a Rockwell harness testing machine with a load of 15 kg and a dwell time of 15s.

4. RESULTS AND DISCUSSIONS A friction stir welding had performed on plates 6111-T4 aluminium alloy of thickness 5mm by cylindrical pin (CLP) of 5 mm diameter and 4.7 mm pin Height at various Rotational speed, welding speed and Shoulder diameter with and without preheating. In following table 3, CLP without thread shows better results of ultimate tensile strength, Hardness, Percentage elongation at 182 Mpa at 1100 rpm, 10 mm/min, 1000 10 15, 1000 10 15 welding speed and 15 mm shoulder diameter respectively. The qualitative and quantitative approaches were selected to analyze and validate the results of friction stir welding joint with and without preheating.

4.1 Quantitative Analysis It has been observed that CLP without thread shows good properties of material joint at increasing rotational speed lower feed and moderate SD. Further, the experimentation has performed to get the welding joint CLP with thread shows better results of UTS, HRC, PL 1000 rpm,15 mm/min,15mm, 1000 rpm, 10 mm/min, 20 mm, 1000 rpm, 15 mm/min, 15mm respectively. FSW with Preheating CLP without Thread at 1000 c UTS, 1000 rpm,15 mm/min, 15 mm, HRC 1000 rpm, 10 mm/min, 20 mm and PEL 1000 rpm, 10 mm/min, 20 mm. respectively. CLP without thread at 1500 c, UTS 1100 rpm, 15 mm/min,15 mm, Hrc 1100 rpm 15 mm/min, 15 mm, Pel 1000 rpm,15 mm/min, 15 mm. CLP with Thread at 1000 c UTS 1000 rpm,15 mm/min 15 HRC 1100 rpm,10 mm/min, 15 mm PEL 1000 rpm, 10 mm/min,15 mm. CLP with thread at 1500 c Uts 1100 rpm,15 mm/min, 20 mm, HRC 1100rpm, 10 mm/min, 15 mm and 1100 rpm,15 mm/min, 15 mm respectively.

Table 3: Responses of FSW on AA 6111 –T4 Weld Joint

1 2 3 4 5

CLP without thread UTS HRC PL

CLP with thread UTS HRC PL

CLP without Thread at 1000 c UTS HRC PL

CLP without thread at 1500 c UTS HRC PL

CLP with Thread at 1000 UTS HRC PEL

CLP with t hread at 1500 c UTS HRC PEL

163 183 179 169 171

189 182 188 188 187

196 196 189 194 193

197 202 208 196 207

210 201 197 198 206

202 207 208 211 202

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67 65 69 73 65

6 3 5 5 3

64 61 63 65 67

7 4 7 6 6

60 58 60 57 62

6 8 6 9 9

61 66 66 64 63

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8 6 7 8 6

61 62 65 64 66

10 11 9 11 8

64 66 64 63 65

9 9 12 12 11

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118 6 7 8

Nitin B Borkar & Dr. S S Deshmukh 182 173 164

73 74 72

3 7 6

184 179 175

66 67 64

6 5 7

195 192 197

59 62 60

8 7 9

196 197 197

61 65 65

7 8 7

206 208 199

66 62 61

12 8 8

201 205 214

67 64 65

11 11 11

4.1.1 Cylindrical Pin without Threading In factorial analysis of the friction stir welding trials on AA 6111-T4, material can be analyzed with the help of following “figures 1”. Pareto chart denotes the contribution of various parameters on UTS, HRC and PEL. As figure 1a shows that the effect of AC means tool rotational speed towards the target of 12 than other parameters individually or combines.

Further in figure 1b, the effect of traverse speed is more on the response like Hardness and remaining parameters are also trending the same individually and combine both. Figure 1c indicates an individual contribution of AC means rotational speed and shoulder diameter. In the figure 1d, 1h, 1k of Box plot of process parameter with respect to ultimate tensile strength of welding joint shows the significant effect individually. Figure 1d,1h indicates that the UTS values are getting downward trend with increasing rotational speed of tool and increasing with marginal increased value of transverse speed of cylindrical pin FSW tool. Further figure 1f,1i,1l indicates the Hardness values are decreasing with increasing RS, increasing with increased TR and decreasing with increased value of SD respectively. The trend of individual parameter for Percentage elongation had analyzed in figure 1g, 1j, 1m and observed that decreasing, increasing, constant with increasing values of RS, TR and SD.

Figure 2: 2 a,2b,2c Factorial Pareto graphs for UTS,HRC,PEL 2d,2h,2k Boxplot graphs UTS with RS,TR,SD 2e,2i,2l Boxplot graphs HRC with RS,TR,SD 2f,2j,2m Boxplot graphs HRC with RS,TR,SD Impact Factor (JCC): 8.8746

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4.1.2 Cylindrical Pin Tool with Thread In qualitative analysis of cylindrical pin with threading, 0.5 mm pitch and 5mm thick plates of 150 mm length and 70 mm width had welded by friction stir welding. The factorial run, as shown in table II were conducted to get the responses as ultimate tensile strength, Hardness, Percentage of elongation. Pareto figures 2a, 2b,2c indicates that contribution of individual parameters and combined parameters. In figure 2d,2g, 2j indicates that ultimate tensile strength had increased, increases increasing with increasing RS,TR,SD respectively. Also figure 2e, 2h, 2k indicates that Hardness of joint increases, increases, decreases with increasing RS,TR and SD respectively. Further figure 2f, 2k, 2m indicates that increasing, constant, constant with increasing SR,TR and SD respectively.

Figure 3: 3 a,3b,3c Factorial Pareto graphs for UTS, HRC,PEL 3d,3h,3k Boxplot graphs UTS with RS, TR, SD 3e,3i,3l Boxplot graphs HRC with RS, TR, SD 3f,3j,3m Boxplot graphs HRC with RS, TR, SD 4.1.3 CLP without Thread Preheating at 1000 c In qualitative analysis of cylindrical pin without threading of 0.5 mm pitch and 5mm thick plates of 150 mm length and 70 mm width had welded by friction stir welding with preheating at 1000 c. The factorial run, as shown in table II were conducted to get the responses as Ultimate tensile strength, Hardness, Percentage of elongation. Pareto figures 3a, 3b, 3c indicates that contribution of individual parameters and combined parameters. In figure 3d, 3g,3j indicates that ultimate tensile strength had increased, decreasing, increasing with increasing RS,TR,SD respectively. Also figure 3e, 3h,3k indicates that Hardness of joint increases, increases, increasing with increasing RS,TR and SD respectively. Further, figure 3f,3i,3m indicates that increasing, decreasing, decreasing with increasing SR,TR and SD respectively.

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Figure4: 4 a,4b,4c Factorial Pareto graphs for UTS,HRC,PEL 4d,4h,4k Boxplot graphs UTS with RS,TR,SD 4e,4i,4l Boxplot graphs HRC with RS,TR,SD 4f,4j,4m Boxplot graphs HRC with RS,TR,SD 4.1.4 CLP with Thread at 1500 c In qualitative analysis of cylindrical pin without threading of 0.5 mm pitch and 5mm thick plates of 150 mm length and 70 mm width had welded by friction stir welding with preheating at 150 0 c. The factorial run, as shown in table II were conducted to get the responses as Ultimate tensile strength, Hardness, Percentage of elongation. Pareto figures 4a,4b,4c indicates that contribution of individual parameters and combined parameters. In figure 4d,4g,4j indicates that ultimate tensile strength had decreasing, decreasing, increasing with increasing RS,TR,SD. Also figure 4e,4h,4k indicates that Hardness of joint decreasing, increases, increasing with increasing RS,TR and SD respectively. Further figure 4f, 4i, 4m indicates that increasing, increasing, increasing with increasing SR,TR and SD respectively.

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Figure 5: 5a,5b,5c Factorial Pareto graphs for UTS,HRC,PEL 5d,5h,5k Boxplot graphs UTS with RS,TR,SD 5e,5i,5l Boxplot graphs HRC with RS,TR,SD 5f,5j,5m Boxplot graphs HRC with RS,TR,SD 4.1.5 CLP with Thread at 1000 c Preheating In qualitative analysis of cylindrical pin without threading of 0.5 mm pitch and 5mm thick plates of 150 mm length and 70 mm width had welded by friction stir welding with preheating at 150 0 c. The factorial run, as shown in table II were conducted to get the responses as Ultimate tensile strength, Hardness, Percentage of elongation. Pareto figures 5a, 5b, 5c indicates that contribution of individual parameters and combined parameters. In figure 5d,5g,5j indicates that ultimate tensile strength had increased, increases, increasing with increasing RS,TR,SD respectively. Also figure 5e, 5h, 5k indicates that hardness of joint with decreasing, decreasing, decreasing increasing RS, TR and SD respectively. Further. figure 5f,5i,5m indicates that constant, constant, increasing with increasing SR,TR and SD respectively.

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Figure 6: 6a,6b,6c Factorial Pareto graphs for UTS,HRC,PEL 6d,6h,6k Boxplot graphs UTS with RS,TR,SD 6e,6i,6l Boxplot graphs HRC with RS,TR,SD 6f,6j,6m Boxplot graphs HRC with RS,TR,SD 4.1.6 CLP with Thread at 1500 c Preheating The cylindrical pin with threading of 0.5 mm pitch and 5mm thick plates of 150 mm length and 70 mm width had welded by friction stir welding with preheating at 1500 c had conducted over 6111-T4 Alloy. The factorial runs, as shown in table II were conducted to get the responses as Ultimate Tensile Strength (UTS), Hardness (HRC), Percentage of elongation ().

Pareto figures 6a, 6b,6c indicates that contribution of individual parameters and combined parameters. In figure 6d, 6g, 6j indicates that ultimate tensile strength had increased, increases, increasing with increasing RS,TR,SD respectively. Also figure 6e, 6h, 6k indicates that Hardness of joint with decreasing, decreasing, decreasing increasing RS,TR and SD respectively. Further, figure 6f, 6i, 6m indicates that constant, constant, increasing with increasing SR,TR and SD respectively.

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Figure 7: 7 a,7b,7c Factorial Pareto graphs for UTS,HRC,PEL 7d,7h,7k Boxplot graphs UTS with RS,TR,SD 7e,7i,7l Boxplot graphs HRC with RS,TR,SD 7f,7j,7m Boxplot graphs HRC with RS,TR,SD. 4.2 Regression Equation for Process Parameters Regression equation for responses of FSW conducted over 6111-T4 material by AISI 1020 (Oil Hardened) steel were found to be for different cases with and without preheating of Aluminium plate alloys. The various combinations of Rotational Speed of Tool, Transverse Rotation, Shoulder diameter are formulated by regression equations for various responses like UTS, HRC, PEL of welded joint, as mentioned in following table. The predicted values of UTS, HRC and PEL by using regression equation as idenfied from following table. With reference to predicted values of responses, experimentation had conducted to validate the regression approximation of FSW of 6111-T4 welded joint. It has been observed from table that fsw tool with and without preheating and cylindrical pin with and without tread shows significant effect on ultimate tensile strength, Hardness of joint and percentage elongation of a welding specimen. The optimal conditions for UTS, HRC and PEL are 212.5 Mpa,66.89 Hrc and 11.42 % of elongation at RS 1000 RPM,TR 10 mm/min and SD 20 mm with preheating at 1500 c and cylindrical threaded pin with 0.5 mm of pitch.

CLP without thread UTS,HRC,PEL CLP with thread UTS,HRC,PEL

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Table 4: Regression Equation for UTS, HRC and PEL Exp. UTS = 175.28 HRC=77.86 Prd. UTS = 177.5 HRC= 88.7 PEL=5.5 PEL=4.69 PEL = 14.0 HRC = 71.2 - 0.005 0.01 RS + 0.1 UTS = 192 - 0.035 RS + 1.10 TR + 0.20 SD (1) RS + 1.00 TR - 0.5SD TR + 0.0 SD(2) (3) Exp. UTS =185.96 HRC= 70.85 Prd.UTS = 190.5 HRC = 64.7 PEL=6.2 PEL=5.18 HRCT1 = 52.7 + PEL T1 = 0.7 + UTS T1 = 98.0 + 0.06 RS +0.3TR + 1.1SD (4) 0.0175 RS + 0.25 0.005 RS + 0.000

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TR - 0.550 SD (5)

TR + 0 SD (6)

Exp. UTS =195.1 HRC= 64.98 PEL=7.5 PEL PR = 12.7 HRC PR = 30.2 + + 0.00000 RS UTS,HRC,PEL UTS PR = 189 +0.0075 RS -0.05TR -0.15SD (7) 0.0175 RS+ 0.05TR - 0.300 TR +0.55SD (8) 0.1 SD (9) Prd.UTS = 202 HRC= 66.45 Exp. UTS = 201.88 0 Preheating with CLP without thread at 150 c PEL=7.75 HRC= 64.59 PEL=8.87 HRC PR2 = 94.7 PEL PR2 = 0.032 1.75+ 0.0025 UTS,HRC,PEL UTS PR2 = 219 -0.02 RS - 0.3TR + 0.3SD (10) RS+0.05TR+0.150SD RS+0.15 TR + (11) 0.05 SD (12) Prd.. UTS = 205 Exp. UTS = 208.46 Preheating with CLP with Thread at 1000 HRC = HRC= 62.63 PEL=9.89 64.2 PEL=10 PEL PRT1 = HRC PRT1 = 2.5 + 0.0100 UTS,HRC,PEL UTS PRT1 = 180+.0175RS +1.25 TR-.65SD (13) 63.7+.005RS + 0.1TR RS + 0.100 TR -0.4 SD (14) + 0.0SD (15) Exp. UTS = 212.5 Preheating with CLP with thread Prd.. UTS = 210 HRC = 67.5 PEL=10.5 HRC= 66.89 at 1500 c PEL=11.42 HRC PRT2 = 17b+ PEL PRT 2 = 0.0375 18-.012RS UTS,HRC,PEL UTS PRT2 = 222-0.025RS+0.1TR+0.6SD(16) RS+0.55TR+0.05SD +0.35TR+0.05 (17) SD (18) Preheating with CLP without Thread at 1000c

Prd. UTS= 193.75 HRC = 61.2 PEL=8.2

4.3 Qualitative Analysis The base metal microstructure is shown in “Table 5”, it consists of course and elongated grains with dark precipitates present in grain boundaries of joint 6111-T4 joint. The microstructures of Stir zone (SZ), thermo-mechanical affected zone (TMAZ) and heat affected zone (HAZ) of all welds were studied under metallurgical microscope at 100x magnification.

Physical Examinations of samples of weld joint (PRT joint), low aspect ratio coarse grains is observed in the shoulder affected region, these grains are coarser than that of in the middle SZ region observed the weld joint defects. The finer grains are observed in the pin affect region than that in middle stir zone region it is due to sufficient stirring action caused by tool.

Table 5: Qualitative Results of Responses after FSW of 6111-T4 Alloys

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5. CONCLUSIONS In this Qualitative and Quantitative investigations, some of the facts and measures were identified for the control process parameters on significant mechanical properties like Tensile Strength, Harness and percentage elongation for 6111-T4 aluminium alloys joint. It was investigated by using Factorial Design method and ANOVA analysis with Pareto plot and box plot figures. The regression equation estimated the optimal conditions for joint is achieved when values of travel speed, rotational speed, Shoulder diameter were 1000 rpm, 15mm/min, 20 mm respectively. In such conditions Tensile strength and % Elongation of a joint were 210 Mpa, 67.5 Hrc and 10.5 respectively.

Finally, following observations were noted after analysis of process parameters. 

With increasing tool rotational speed, i.e., at 1100 rpm generates maximum heat at nugget, Hence welding joint achieves maximum ultimate tensile strength during 210 Mpa at CPL with threaded pin and preheating at 1500c.



Hardness of welding joint increases with increasing tool rotational speed and tool travel speed, it can be concluded that the experimental value of hardness 66.89 and percentage elongation up to 11.42%.



Increasing in tool rotational speed 1100 rpm and lower tool travel speed of10 mm/min and lower Shoulder diameter of 15 mm results the higher the values of Ultimate tensile strength, Percentage elongation with best values of S and P in ANOVA analysis.



Regression model verifies the factorial and ANOVA results with 61.33, 64.13,67.17,68.23,71.88,73.13 % for six conditions of process parameters with two welding tool profiles.

ACKNOWLEDGMENTS Welding, macrostructure and micro-hardness analysis, UTS,HRC and PEL test were performed in the SGTR Welding Research lab. at (Shri sant Gajanan Maharaj College of engineering Shgaon –MS., india)

AUTHOR CONTRIBUTIONS Dr. S S Deshmukh and Mr Nitin Borkar had designed the experiments and wrote the paper; Tool design and prepare at Research Lab At SSGMCE shegaon. MS india REFERENCES 1.

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