The optimization of friction spot welding process parameters in AA6181-T4 and Ti6Al4V dissimilar joints |
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| Affiliation: | 1. Helmholtz-Zentrum Geesthacht, Institute of Materials Research, Materials Mechanics, Solid-State Joining Processes, Max-Planck-Str. 1, Geesthacht, Germany;2. Federal University of São Carlos, Materials Engineering Department, R. Washington Luís Km 235 – SP 310, Sao Carlos, Brazil;3. Federal University of Rio Grande do Sul, Mechanical Engineering Department, Av. Paulo Gama, 110 Farroupilha, Porto Alegre, Brazil;1. Structural Integrity Group, Escuela Politécnica Superior, Avenida Cantabria s/n, 09006 Burgos, Spain;2. Civil Engineering Department, University of Burgos, Calle Villadiego s/n, 09001 Burgos, Spain;1. School of Materials and Energy, Guangdong University of Technology, Guangzhou 510006, PR China;2. School of Electrical and Electronic Engineering, Nanyang Technological University, Singapore 639798, Singapore;3. State Key Laboratory of Electronic Thin Films and Integrated Devices, University of Electronic Science and Technology of China, Chengdu 610054, PR China;1. School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Tehran, Iran;2. Department of Materials Engineering, Science and Research Branch, Islamic Azad University, Kermanshah, Iran;1. Department of Materials Science and Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USA;2. Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76203, USA;3. Rolls-Royce Corporation, Indianapolis, IN 46241, USA;4. The Boeing Company, St. Louis, MO 63166, USA;1. State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China;2. Department of Materials Science and Engineering, The Pennsylvania State University, University Park, PA 16802, USA |
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| Abstract: | Friction spot welding is a relatively new solid-state joining process able to produce overlap joints between similar and dissimilar materials. In this study, the effect of the process parameters on the lap shear strength of AA6181-T4/Ti6Al4V single joints was investigated using full-factorial design of experiment and analyses of variance. Sound joints with lap shear strength from 4769 N to 6449 N were achieved and the influence of the main process parameters on joint performance was evaluated. Tool rotational speed was the parameter with the largest influence on the joint shear resistance, followed by its interaction with dwell time. Based on the experimental results following response surface methodology, a mathematical model to predict lap shear strength was developed using a second order polynomial function. The initial prediction results indicated that the established model could adequately estimate joint strength within the range of welding parameters being used. The model was then used to optimize welding parameters in order satisfy engineering demands. |
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| Keywords: | Friction spot welding Aluminum alloy Titanium alloy Dissimilar joint Design of experiments Response of surface methodology |
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