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An investigation into optimizing the friction stir welding factors (FSWF) for yellow brass

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Abstract

Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. In this research, FSW is successfully executed for yellow/naval brass 405–20 that has ample applications in plumbers’ flanges, fittings, ornamental, hardware, and ship trim. Moreover, both the naval brass 405–20 and the tool material (M2 HSS) utilized are novel. The effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters, i.e., weld temperature, weld strength, and weld hardness. Three levels of both rotational speed (1300, 1450, and 1600) rpm and traverse speed (40, 50, and 60) mm/s were selected in this work to execute full factorial design of experiments (DOEs). The highest weld temperature developed while FSW was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 106.37% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in optimal temperature, optimal strength, and optimal hardness. Rotational speed (RS) was also found to be significant only towards the weld temperature at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Moreover, a numerical validation for weld temperature only was also performed along with empirical validations each for temperature, strength, and hardness of joint. The investigation of FSWZ using possible magnification settings of coordinate measuring machine (CMM) and scanning electron microscope (SEM) resulted in findings such as regular circular patterns, thin burrs of welded brass, crazing pores initiating the cracks leading further to joint failure, and likelihood of dezincification within brass.

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Data availability

The data related to experimental findings is already reported within the paper, and it can also be available from corresponding author “Ahmed M. Mehdi” upon a reasonable request.

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Acknowledgements

This work is based on the research initiatives for friction stir welding of brass by the first author, i.e., Syed Farhan Raza and Ahmed Murtaza Mehdi (Corresponding Author). Moreover, the authors are really indebted to the University of Engineering and Technology, Lahore, Pakistan, for the research facilities used in this research. Moreover, a preprint of this manuscript is present online at the research square platform.

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, G.T. Road, Lahore, 54890, Punjab, Pakistan

    Syed Farhan Raza, Kashif Ishfaq, Sadaf Zahoor & Sarmad Ali Khan

  2. Department of Electrical Engineering, Lahore College for Women University (LCWU), Lahore, Punjab, Pakistan

    Muhammad Taskeen Raza

  3. Frazer Institute, Faculty of Medicine, The University of Queensland, 37 Kent Street, Woolloongabba, 4102, Australia

    Ahmed Murtaza Mehdi

Authors
  1. Syed Farhan Raza
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  2. Kashif Ishfaq
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  3. Sadaf Zahoor
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  4. Sarmad Ali Khan
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  5. Muhammad Taskeen Raza
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  6. Ahmed Murtaza Mehdi
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Contributions

Syed Farhan Raza: conceptualization, data analysis, resources, methodology, writing—original draft; Kashif Ishfaq: methodology, data analysis, writing, investigation; Sadaf Zahoor: methodology, data analysis, writing, investigation; Sarmad Ali Khan: review and editing; Muhammad Taskeen Raza: resources, review and editing, data analysis and curation; Ahmed Murtaza Mehdi: review and editing.

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Correspondence to Ahmed Murtaza Mehdi.

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Raza, S.F., Ishfaq, K., Zahoor, S. et al. An investigation into optimizing the friction stir welding factors (FSWF) for yellow brass. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13582-z

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