Skip to main content

Advertisement

SpringerLink
Log in

Optimization of friction stir spot welding process parameters for Al-Cu dissimilar joints using the energy of the vibration signals

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A friction stir spot welding (FSSW) process for dissimilar aluminum alloy AA1050 and pure copper sheets of 3-mm thickness at different tool rotation speeds between 710 and 1800 rpm and dwell time levels of 0, 5, and 10 s were performed in this study. Empirical relationships were developed to predict the shear failure load (joint strength) and the energy of the vibration signals incorporating two of the most important process parameters, tool rotation speed and dwell time. Process parameters were optimized by using the response surface method (RSM); the optimal values of tool rotation speed and dwell time were 1255 rpm and 4 s, respectively. The parameters optimization results were used in a confirmation test; the dissimilar Al/Cu FSSW joints made with optimal parameters exhibit a good shear failure load. The close relationship between the shear failure load (SFL) of the welded joint and the energy of the vibration signals (EVS) generated during FSSW process was demonstrated. This model can be used to develop and optimize the parameters for automatic control of the FSSW process, based on the vibration signal generated.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Mehta KP, Badheka VJA (2016) Review on dissimilar friction stir welding of copper to aluminum: process, properties, and variants. Mater Manuf Process 31:233–254

    Article  Google Scholar 

  2. Macías E, Roca A, Fals H, Muro J, Fernández J (2015) Characterisation of friction stir spot welding process based on envelope analysis of vibro-acoustical signals. Sci Technol Weld Join 20:172–180

    Article  Google Scholar 

  3. Bergmann JP, Petzoldt F, Schürer R, Schneider S (2013) Solid-state welding of aluminum to copper—case studies. Weld World 57:541–550

    Article  Google Scholar 

  4. Mubiayi MP, Akinlabi ET (2015) An Overview on Friction Stir Spot Welding of Dissimilar Materials. In: H.K. Kim et al. (eds.), Transactions on Engineering Technologies, Springer Netherlands, pp 537–49

  5. Heideman R, Johnson C, Kou S (2010) Metallurgical analysis of Al/Cu friction stir spot welding. Sci Technol Weld Join 15:597–604

    Article  Google Scholar 

  6. Özdemir U, Sayer S, Yeni Ç (2012) Effect of pin penetration depth on the mechanical properties of friction stir spot welded aluminum and copper. Mater Test 54:233–239

    Article  Google Scholar 

  7. Shiraly M, Shamanian M, Toroghinejad M, Jazani MA (2014) Effect of tool rotation rate on microstructure and mechanical behavior of friction stir spot-welded Al/Cu composite. J Mater Eng Perform 23:413–420

    Article  Google Scholar 

  8. Manickam S, Balasubramanian V (2015) Maximizing strength of friction stir spot welded bimetallic joints of Aa6061 aluminum alloy and copper alloy by response surface methodology. Int J Mech Eng 3-12:15–26

    Google Scholar 

  9. Abbass MK, Hussein SK, Khudhair AA (2016) Optimization of mechanical properties of friction stir spot welded joints for dissimilar aluminum alloys (Aa2024-T3 and Aa 5754-H114). Arab J Sci Eng 1–10:4563–4572

    Article  Google Scholar 

  10. Effertz P, Quintino L, Infante V (2017) The optimization of process parameters for friction spot welded 7050-T76 aluminium alloy using a Taguchi orthogonal Array. Int J Adv Manuf Technol 91(9–12):3683–3695

    Article  Google Scholar 

  11. Babu KK, Panneerselvam K et al (2018) Parameter optimization of friction stir welding of cryorolled AA2219 alloy using artificial neural network modeling with genetic algorithm. Int J Adv Manuf Technol 94(9–12):3117–3129

    Article  Google Scholar 

  12. Sundaram M, Visvalingam B (2016) Optimizing the friction stir spot welding parameters to attain maximum strength in Al/Mg dissimilar joints. J Weld Join 34(3):23–30

    Article  Google Scholar 

  13. Orozco MS, Macías EJ, Roca AS, Fals HC, Fernández JB (2013) Optimisation of friction-stir welding process using vibro-acoustic signal analysis. Sci Technol Weld Join 18:532–540

    Article  Google Scholar 

  14. Chen C, Kovacevic R, Jandgric D (2003) Wavelet transform analysis of acoustic emission in monitoring friction stir welding of 6061 aluminum. Int J Mach Tools Manuf 43:1383–1390

    Article  Google Scholar 

  15. Fernández JB, Roca AS, Fals HC, Macías EJ, Parte MPDL (2012) Application of vibroacoustic signals to evaluate tools profile changes in friction stir welding on Aa 1050 H24 alloy. Sci Technol Weld Join 17:501–510

    Article  Google Scholar 

  16. Zhang Z, Yang X, Zhang J, Zhou G, Xu X, Zou B (2011) Effect of welding parameters on microstructure and mechanical properties of friction stir spot welded 5052 aluminum alloy. Mater Des 32:4461–4470

    Article  Google Scholar 

  17. Bozzi S, Helbert-Etter A, Baudin T, Criqui B, Kerbiguet J (2010) Intermetallic compounds in Al 6016/IF-steel friction stir spot welds. Mater Sci Eng A 527:4505–4509

    Article  Google Scholar 

  18. Khan MI, Kuntz ML, Su P, Gerlich A, North T, Zhou Y (2007) Resistance and friction stir spot welding of DP600: a comparative study. Sci Technol Weld Join 12(2):175–182

    Article  Google Scholar 

  19. Rajakumar S, Muralidharan C, Balasubramanian V (2010) Establishing empirical relationships to predict grain size and tensile strength of friction stir welded AA 6061-T6 aluminium alloy joints. T Nonferr Metal Soc 20(10):1863–1872

    Article  Google Scholar 

  20. Benavides S, Li Y, Murr LE, Brown D, McClure JC (1999) Low-temperature friction-stir welding of 2024 aluminum. Scr Mater 41(8):809–815

    Article  Google Scholar 

  21. Dashatan SH, Azdast T, Ahmadi SR, Bagheri A (2013) Friction stir spot welding of dissimilar polymethyl methacrylate and acrylonitrile butadiene styrene sheets. Mater Des 45:135–141

    Article  Google Scholar 

  22. Yuan W, Mishra RS, Webb S, Chen Y, Carlson B, Herling D, Grant G (2011) Effect of tool design and process parameters on properties of Al alloy 6016 friction stir spot welds. J Mater Process Technol 211:972–977

    Article  Google Scholar 

Download references

Funding

This paper has been partially supported by the project of the Spanish Government, DPI2011-25007: “Friction Stir Welding of Dissimilar Materials. Characterization by Acoustic Emission Techniques and Artificial Intelligence.”

Author information

Authors and Affiliations

  1. Faculty of Mechanical Engineering, Universidad de Oriente, Ave. Las Américas s/n, CP 90900, Santiago de Cuba, Cuba

    Alberto Nacer Colmenero, Mario Sánchez Orozco, Hipólito Carvajal Fals & Angel Sánchez Roca

  2. Electrical Engineering Department, Universidad de La Rioja, Logroño, La Rioja, Spain

    Emilio Jiménez Macías & Juan Carlos Sáenz-Diez Muro

  3. Mechanical Engineering Department, Universidad La Rioja, Logroño, La Rioja, Spain

    Julio Blanco Fernández

Authors
  1. Alberto Nacer Colmenero
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mario Sánchez Orozco
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Emilio Jiménez Macías
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Julio Blanco Fernández
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Juan Carlos Sáenz-Diez Muro
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Hipólito Carvajal Fals
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Angel Sánchez Roca
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mario Sánchez Orozco.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Colmenero, A.N., Orozco, M.S., Macías, E.J. et al. Optimization of friction stir spot welding process parameters for Al-Cu dissimilar joints using the energy of the vibration signals. Int J Adv Manuf Technol 100, 2795–2802 (2019). https://doi.org/10.1007/s00170-018-2779-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2779-y

Keywords

Search

Navigation