AN EXPERIMENTAL STUDY ON FRICTION
STIR WELDING OF ALUMINUM-
MAGNESIUM ALLOYS FOR IMPROVED
MECHANICAL PROPERTIES OF TAILOR
WELDED BLANKS
Manoj M. Joshi
Assistant Professor, Department of Mechanical Engineering, Sinhgad College of
Engineering, Pune, Research scholar, Mechanical Engineering, SPPU, Rajarshi
Shahu college of Engineering, Pune, India
manojmjoshi17@gmail.com
Dr. Amol Ubale
Professor, Department of Mechanical Engineering, Zeal College of Engineering,
Pune, Research Guide, SPPU, Rajarshi Shahu college of Engineering, Pune, India
amol.ubale@zealeducation.com:
Reception: 20/11/2022 Acceptance: 14/01/2023 Publication: 12/02/2023
Suggested citation:
M. J., Manoj and U., Amol. (2023). An Experimental Study On Friction
Stir Welding Of Aluminum-Magnesium Alloys For Improved
Mechanical Properties Of Tailor Welded Blanks. 3C Empresa.
Investigación y pensamiento crítico, 12(1), 346-359. https://doi.org/
10.17993/3cemp.2023.120151.346-359
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ABSTRACT
Tailor welded blanks (TWB) are used in automotive and aerospace industries as they
offer weight saving followed by cost saving and improved fuel economy. Being light in
weight and having low cost, Aluminum alloys have piqued the interest of scientists.
Friction Stir Welding (FSW) is a well-known accepted technique used since 1991
worldwide for Aluminum and its alloys. Due to friction stir welding, mechanical
changes occur due to stirring action at the joint. Also the inter-metallic compounds,
kissing bond formation, onion ring formation etc. are defects encountered in the
nugget zone of welding. Hence, a novel technique is suggested to carry out the
friction stir welding using a blend of techniques viz. double sided friction stir welding
and multi objective optimization of process parameters. For experimentation, AA 5182
and AA 5754-Aluminum Magnesium alloys of 5000 series are used with sheet size of
1.5 mm thickness. Experimentation was carried out on a vertical machining center,
with circular, square, and triangular tool pin profiles with a tool rotational speed range
between 1500 -1800 rpm and a welding speed range of 40 mm/min.-60 mm/min. For
the analysis purpose, L9 orthogonal array was used and Grey Relational
Analysis(GRA) was employed and ASTM standards were used for tensile testing.
Base sample materials of AA 5182 and AA5754 are having ultimate tensile strengths
of 289.58 N/mm2 and 220.75N/mm2respectively. The designed welded blank of the
two materials recorded maximum ultimate tensile strength of 268.11N/mm2which was
remarkable for FSW. Welded joint efficiency was found to be 92.73% and percentage
elongation of TWB was found to be 44% as compared to the base metals.
KEYWORDS
Grey relational analysis, Double sided friction stir welding, Tensile Strength,
Percentage Elongation.
PAPER INDEX
ABSTRACT
KEYWORDS
1. INTRODUCTION
2. MATERIAL AND EXPERIMENTAL METHOD
2.1. TENSILE TEST
3. RESULTS AND DISCUSSIONS
3.1. GREY RELATIONAL COEFFICIENT CALCULATION
4. CONCLUSION
ACKNOWLEDGMENT
REFERENCES
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1. INTRODUCTION
To achieve cost reduction and improved fuel efficiency, dissimilar materials of
variable strengths can be employed at various locations in the automotive body.
Nowadays, aluminum and its alloys are widely used in automobile body components.
Due to the scarcity of aluminum in the market, it is frequently mixed with Magnesium
to offer adequate strength. As custom welded blanks, aluminum-magnesium alloys
with high specific strength, corrosion resistance, and a low weight-to-density ratio are
employed. Due to metallurgical constraints, fusion welding of these Aluminum-
Magnesium alloys is not practicable. Tailor Welded Blanks of dissimilar materials are
frequently utilized to decrease cost, weight, and improve mileage in automobiles.
Friction Stir Welding is a solid state joining technology that is more effective than
fusion welding at joining dissimilar materials. A properly welded joint characteristics
are dependent on a number of process parameters like, tool rotational speed, pin
profile, shoulder shape, and welding speed [1]. Aluminum alloys, which are lighter in
weight, more durable, and have better corrosion resistance, have largely supplanted
steel in recent years.
Friction Stir Welding was invented by The Welding Institute in 1991.In the case of
aluminum alloys, friction stir welding (FSW) has been found to be a better welding
technique. However, as hardness increases in the weld zone, oxide formation is
noticed in the Nugget Zone (NZ), residual stresses, kissing bond development, and
production of intermetallic compounds are observed in the weld region. To establish a
good welded joint is a difficulty that practically all researchers confront. FSW is being
studied in order to improve welded joints. Many researchers have suggested multi-
objective optimization of process parameters and double-sided friction stir welding
approaches to solve faults in the welded connection.
Yuvaraj et al. [1] performed friction stir welding of dissimilar materials of AA7075-
T651 and AA 6061 alloys using different FSW parameters and found that square pin
profile gave higher strength, whereas Haribalaji et al. [2] used friction stir welding on
input parameters and machine nature. Researchers Klos et al.[3] and Kaushik et al.
[4] investigated the effects of tool pin profiles, feed rate, tool tilt angle, and welding
speed, as well as a review of the mechanical and metallurgical characteristics of
friction stir welded connections. They analyzed that there were micro structural
changes which were found in AA 6063 when combined with SiC particles. The usage
of interlayer material in dissimilar Aluminum and Magnesium alloys was studied by
Kumar et al. [5]. But Cabibbo et al. [6] discussed two unique techniques: double-sided
friction stir welding and RT type pin arrangement. The utility of aluminum magnesium
alloys was explored in depth, as well as the metallurgical changes that occur and the
utility of these Al-Mg alloys in diverse applications such as marine, automotive, and
aerospace [7,8] was studied. Different materials to reduce weight of automotive parts
were discussed by Miklos Tisza et al. [7]. Rahmatian et al. [9] investigated double-
sided friction stir welding on AA 5083 in terms of various process factors. Das B. et al.
[10] employed temperature signal as an approach and experimented with different tool
pin profiles. Researchers [2,11,12,13] also discussed and utilized Grey Relational
Analysis (GRA) to optimize process parameters for a better weld joint. Microstructural
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analysis using X-ray diffraction (XRD) and Scanning Electron Microscopy(SEM)
confirmed that the joint was successful.
Some statistical process parameters were studied by few researchers and
evidences were found in the open literature. The Taguchi method of optimization was
utilized to optimize process parameters for Al- Mg-Si-Cu) alloys of the Aluminum 5000
and 6000 families for future automotive applications by researchers and researchers
have focused on double friction stir welding technique and microstructure analysis at
nugget zone [14,15,16,17]. During mechanical testing, Lee et al. [18] produced a
hybrid composite material from carbon reinforced polymers on CR 340 plates and
discovered epoxy leaks and significant gaps. Marco Parente et al. [11] concluded that
TWB (Tailor Welded Blank) formability was reliant on weld line orientation, and its
formability was lowered. A pin with a square pin profile was proven to be more
effective than any other tool pin profile [19]. Kesharwani et. al. [16] used a Taguchi
grey-based technique to multi-objective optimizes two sheet samples of AA 5052-H32
and AA 5754-H22. Experiments were designed using the L9 orthogonal array. Babu K.
V., et al. [20] designed an expert system based on Artificial Neural Network (ANN) to
analyze deep drawing behavior of Aluminum. Homola et al. [21] suggested the use of
laminate plate at areas where lower load is applied to reduce weight in aircrafts. It was
observed that lot of work was investigated on FSW but still there is a scope available
on developing a novel FSW technique. Hence, using blend of techniques a new
method is developed which will improve the mechanical properties of the joint to suit
the requirements of the various applications.
Process factors such as tool rotational speed (rpm), worktable translational speed
(mm/min), tool geometry, tool material, and tool tilt angle can all be changed, and by
optimizing the process parameters, a good welded junction with good tensile strength
and percentage elongation can be created. Double sided friction stir welding and multi
objective optimization of process parameters are the methodologies which are
blended to develop new Friction Stir Welding(FSW) method. The mechanical qualities
and formability of this FSW joint are excellent.
Taking cognizance of all above discussions based on research literature availability,
it was finalized to use an innovative combination of AA 5182, AA 5754 materials of 1.5
mm thickness to prepare a tailor welded blank and in order to get better mechanical
properties of the tailor welded blanks, it was decided to use a novel technique of using
double sided fiction stir welding with multi objective optimization of a
few prominent and important process parameters viz. tool rotational speed (rpm),
worktable translational speed (mm/min), tool geometry to get better welded joint with
better mechanical properties.
2. MATERIAL AND EXPERIMENTAL METHOD
By taking application into consideration, Aluminum-Magnesium Alloys Viz. AA 5182
and AA 5754 are
used for experimentation purpose. These materials possess high
specific strength, a low weight-to-density ratio, and a moderate strength, ductility and
corrosion resistance. As pure Aluminum is scarce in the market, it is frequently mixed
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with Magnesium. They have moderate strength, high ductility, and very good corrosion
resistance, wrought Al-Mg alloys are used as structural materials mainly in automobile
industries.
Aluminum is soft and brittle by itself, but it can be strengthened by adding minor
amounts of copper,
magnesium, and silicon to the alloy. The Audi A8, Rolls Royce
Phantom, and BMW Z8 all use the 5182
aluminum alloy [21]. Magnesium and
manganese are minor components in the 5182 aluminum alloy. The aluminum alloy
5182 is used in the automobile industry to make a variety of parts.5754 Aluminum
alloy
is a common material in the automotive sector (vehicle doors, moulds, and
seals). Magnesium is abundant in the 5000 class of aluminum alloys, which are non-
heat treatable. Aluminum is soft and brittle in its pure form, but it can be strengthened
by adding minor amounts of magnesium, copper, and silicon [21]. The Al-Mg-Si alloy
5182 is a type of aluminum alloy. It’s a moderately strong alloy with good corrosion
resistance, weld ability, and cold processing properties. The 5754 aluminum alloy has
a medium strength,
excellent processing properties, excellent corrosion resistance,
weld ability, and ease of processing and forming. AA 5754 is Al-Mg alloy and AA 5754
is widely used in the automotive industry.
Experimentation was carried out on the material chosen and lab testing of base
metal is done. The properties of the sample are shown in table 1 as follows:
Table 1. Composition of Elements of Aluminum Sheets
2.1. TENSILE TEST
Tensile test specimens of the basic material: AA 5182 and AA 5754 sheets are
taken according to ASTM
E8M standards, as illustrated in fig. 1. Composition of the
parent Aluminum alloys is enlisted in Table
1. Tensile tests were performed on AA
5182 and AA 5754 materials. Figure 1 shows the sample sizes obtained which adhere
to ASTM E8 M standards. As shown in figure 2, a friction stir welding tool made up of
Elements
AA
5182
AA5
754
% Observed
% Specified
% Observed
% Specified
Copper 0.005 0.15 max. 0.004 0.10 max
Magnesium
5.82
4.00/5.00
3.09
2.6
Silicon
0.059
0.20 max
0.199
0.40 max
Iron
0.126
0.35 max
0.492
0.40 max
Manganese
0.449
0.20
0.030
0.5 max
Zinc 0.006 0.25 max. - -
Titanium
0.009
0.10 max
-
-
Chromium
0.063
0.30 max
0.179
0.30 max
Aluminum 93.26 93.2 max 95.71 87.1
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materials. A 100 kN computerized universal testing machine is employed to carry out
the tensile test.
Figure 1. ASTM E8 Tensile Testing Specimen Figure 2. Friction Stir Welding(FSW)Tool
Table 2. Tensile test result of AA 5182 and AA 5754 sheets
from 1.5 mm thick
pins, such as circular, square, and triangular, are utilized as shown in figure 3. Double-
sided friction stir welding is done for making test
advancing side (A.S.) (Al Alloy AA5182) is the side when the tool
directions are the same, whereas the retreating side is the opposite (R.S.) (Al alloy
metals
understanding about advancing and retreating side.
Parameter AA 5182 AA5754
Specimen Type Flat Flat
Cross section area(mm2) 62.850 62.850
Original gauge Length 50 50
Final gauge Length 50 50
Preload(%) 0.2 0.2
Ultimate tensile load(kN) 18.200 14.44
Ultimate Tensile Strength (N/mm2) 209.577 229.752
Displacement at Ultimate load(mm) 12 5.5
Maximum Displacement(mm) 13.2 7.9
Percentage Elongation(%) 22.2 13.240
Breaking Load (kN) 17.240 12.920
Breaking Stress(N/mm2) 274.302 205.667
Yield Load(kN) 11.920 12.120
Yield stress(N/mm2) 189.658 192.840
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As indicated in table 3, the Taguchi L9
the factors and levels
parameters used during experimentation are shown in
Stir Welded (DSFW) samples of200 mm x 100 mm are cut from each of
samples using the
whereas figure 5 is showing tensile test specimens.
Figure 3. Different tool pin profiles
Figure 4 (A & B). Advancing and retreating side in Friction Stir Welding
Table 3. Factors and Levels
Square Profile
Triangular Profile
Circular Profile
Sr.
No.
Rotational Speed of
tool (rpm)
Worktable feed (mm/
min.)
Cross Sectional Shape
of pin
Level 1 1500 40 Circular
Level 2 1650 50 Triangular
Level 3 1800 60 Square
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Figure 5. Tensile test specimen of TWB
Table 4. Taguchi L9 orthogonal input array
3. RESULTS AND DISCUSSIONS
Grey Relational Analysis (GRA) is used in the multi-objective optimization of
process parameters, and all samples are prepared using double-sided friction stir
welding. The samples with the best ultimate tensile strength and percent elongation
are determined.
Experimental readings are normalized in the range from zero to one. The two
output parameters, weld strength and ductility values, are dealt with in the grey
relational analysis. The results of the tests should be normalized in the range of 0 to 1.
Grey relational coefficients and then grey relational grades are computed after
normalizing. The higher value of grey relational grade is used to determine the optimal
level of each process parameter. The most important controllable element and less
important controllable parameters are determined by this technique.
Sr.N
o.
Rotational
Speed of tool
(rpm)
(A)
Work table
feed(mm/
min.) (B)
Cross
sectio
nal
shape
FSW
designat
ion
1
1500
40
Circular
L
9
_1111
2
1500
50
Triangular
L
9
_1222
3
1500
60
Square
L
9
_1333
4
1650
40
Square
L
9
_2123
5
1650
50
Circular
L
9
_2231
6
1650
60
Triangular
L
9
_2312
7
1800
40
Triangular
L
9
_3132
8
1800
50
Square
L
9
_3213
9
1800
60
Circular
L
9
_3321
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3.1. GREY RELATIONAL COEFFICIENT CALCULATION
Table 5. GRA Grey Relational Analysis Data Set
Table 5 is giving the experimental results obtained. Three such sets of readings of
Ultimate Tensile strength and % elongation corresponding to the set of parameters
used sequentially from Taguchi L9 orthogonal input array(table 4) are shown in table
no.5.
Table 6. Normalized data
Table 6 indicates the normalized values. Both ultimate tensile strength and %
elongation are better if they are larger. Normalization values are obtained using
formula with the help of data available from table 5.
(1)
(I) GRA GREY RELATION ANALYSIS
DATA SET
UTS % Elongation
SR.NO. A B C D E F
1 243.716 268.11 238.47 5.87 3.33 5.33
2 51.667 21.333 88.667 0.83 1.13 2.66
3 98.333 10.889 90.367 1.14 2.31 2.65
4 146.667 160.78 208.743 3.56 3.12 4.01
5 222.556 182.89 73.446 3.43 2.71 0.61
6 234.754 186.44 237.333 0.88 4.35 10.53
7 124.778 241.89 75.956 2.04 10.86 11.8
8 157.444 233.11 61.222 2.34 10.32 0.28
9 192.222 235.22 233.889 2.62 8.38 8.62
A B C D E F
1.0000 1.0000 1.000
0
1.0000 0.2261 0.4384
0.0000 0.040
6
0.1548 0.0000 0.0000 0.2066
0.2430 0.000
0
0.1644 0.0615 0.1213 0.2057
0.4947 0.582
7
0.8323 0.5417 0.2045 0.3238
0.8898 0.668
7
0.0690 0.5159 0.1624 0.0286
0.9533 0.682
5
0.9936 0.0099 0.3309 0.8898
0.3807 0.898
1
0.0831 0.2401 1.0000 1.0000
0.5508 0.863
9
0.0000 0.2996 0.9445 0.0000
0.7319 0.872
1
0.9742 0.3552 0.7451 0.7240
v
0ik= 1 −
ma x .x0
i
(k)−x0
i
(k)
ma x x0i(k)−min .x0i(k)
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Here,
= 1 to n and
= 1 to n and
=trial number which is 1 to 9.
= performance
characteristic,
=value in normalized data table,
=value from table 1
Table 7. Deviation sequence
Deviation sequence in Table 7 is obtained by formula,
(2)
=Value in deviation sequence table 7, =value in normalized data table, = 1 to n
and =trial number which is 1 to 9. = performance characteristic
Table 8. Grey relation coefficient
Grey relation coefficient is calculated by following formula
(3)
Here, =values of grey relation coefficients. =Value in deviation sequence table 7.
=value in normalized data table, = 1 to n and =trial number which is 1 to 9. =
performance characteristic
A B C D E F
0.0000 0.0000 0.0000 0.0000 0.7739 0.5616
1.0000 0.9594 0.8452 1.0000 1.0000 0.7934
0.7570 1.0000 0.8356 0.9385 0.8787 0.7943
0.5053 0.4173 0.1677 0.4583 0.7955 0.6762
0.1102 0.3313 0.9310 0.4841 0.8376 0.9714
0.0467 0.3175 0.0064 0.9901 0.6691 0.1102
0.6193 0.1019 0.9169 0.7599 0.0000 0.0000
0.4492 0.1361 1.0000 0.7004 0.0555 1.0000
0.2681 0.1279 0.0258 0.6448 0.2549 0.2760
Z0ik=ma x .y0ik
Grey relation coefficient
1.0000 1.0000 1.0000 1.0000 0.3925 0.4710
0.3333 0.3426 0.3717 0.3333 0.3333 0.3866
0.3978 0.3333 0.3744 0.3476 0.3627 0.3863
0.4973 0.5451 0.7488 0.5217 0.3860 0.4251
0.8194 0.6015 0.3494 0.5081 0.3738 0.3398
0.9146 0.6116 0.9873 0.3356 0.4277 0.8193
0.4467 0.8306 0.3529 0.3969 1.0000 1.0000
0.5267 0.7861 0.3333 0.4165 0.9001 0.3333
0.6509 0.7964 0.9509 0.4367 0.6624 0.6443
u
0ik=
min .z0
i
k+ 0.5(ma x .z0
i
k)
z0ik+ 0.5(ma x .z0ik)
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Table 9. Grey Relational Grade
greater value of grey relational grade are found to be optimal. [20]
distortion etc. are out of scope of this article.
•Using grey relational analysis, it was discovered that using
was 5.87 %.
•The reason behind getting
base metals
reaches everywhere leaving no space for oxide formation.
•
289.58 N/mm2 and 220.75 N/mm2, respectively.
•
accomplished.
(GRG) Grey Relational Grade
Ran
k
0.8106 1
0.3501 9
0.3670 8
0.5207 6
0.4987 7
0.6827 3
0.6712 4
0.5494 5
0.6903 2
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4. CONCLUSION
•
By using double sided friction stir welding for joining the dissimilar materials the
harder material was kept on advancing side. The prominent parameters chosen in
this experimentation were tool rotational speed, welding speed and tool geometry.
Tool rotational speed range was 1500 rpm, 1650 rpm and 1800 rpm. The
worktable feed values chosen were 40mm/min., 50 mm/min.,60mm/min.
•At the nugget zone, the mechanical properties are grossly varying as compared to
the other zones, viz. thermos mechanically affected zone, heat affected zone and
parent metal zone.
•While
the tool profiles chosen were circular, square, triangular with tool
material as HSS. Taguchi grey relational analysis
was chosen to find out the
optimized process parameters. Weld strength and ductility values were the output
parameters used in GRA, it was found that
tool rotational speed of 1500 rpm,
worktable translational speed of 40mm/min., circular tool pin profile were
found to be the best process parameters when double friction stir welding
was employed.
•
Further, for the tailor welded blank, the maximum weld strength i.e. tensile
strength obtained was 268.11 N/mm2which is 92.73% and the ductility i.e.
maximum percentage elongation was 44% compared to base metal.
•Double sided welding ensures that there are no voids at the joint and the new stirred
material is leaving no voids at the nugget zone and optimized process parameters
ensure that the welding at the nugget zone is best possible with the optimized
process parameters.
•This novel blended technique of multi objective optimization of prominent process
parameters and use of double sided friction stir welding with harder material on
advancing side of the tool can overcome the usual metallurgical problems.
•Tailor welded blanks can give a better welded joint as the intermixing of the material
is proper at the nugget zone with this technique and oxide formation associated with
brittleness at the joint is also significantly low. Tunnel defect due to improper heat
generation, cavity formation due to uneven mixing of the material, oxide formation at
the joint is reduced to provide weld joint.
Further, Electron Backscatter Diffraction (EBSD) is proposed to check the micro
structure for analysis of lesser ductility which will be the area of Industrial interest.
ACKNOWLEDGMENT
Authors would like to thank MIT World Peace University for offering ACE make
Vertical Machining Centre and Computerized Universal Testing Machine to carry out
friction stir welding and tensile testing. Special thanks to Dr. Ganesh Borikar and Dr.
Anil Mashalkar at MITWPU, Pune for their valuable support. Also, authors would like
to thank Dr. Sagar V. Wankhede, Assistant Professor, School of Mechatronics
Engineering, Symbiosis Skills and Professional University, Pune and Mr.
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Soumyaranjan Nayak-Research Scholar at IIT-B, Dr. R.S. Hingole at D . Y. Patil
College of Engineering, Akurdi, Pune for their valuable inputs.
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