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Study on the Friction Stir Extrusion Process of AA1050 Aluminum Alloy Wires Using Numerical Modelling and Taguchi Method

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Abstract

In this study, a numerical model was presented for the friction stir extrusion process as a new method to produce wire from AA1050 aluminum alloy. First, the proposed model was developed using the commercial simulation package “3D DEFORM” based on finite element analysis and Lagrangian implicit solver. Subsequently, the model was validated against experimental temperature measurements. Moreover, Taguchi experiment design method and standard L9 orthogonal array were used to investigate the effect of process parameters on the obtained outputs. Input variables included rotational speed (RS), plunge rate (PR) and extrusion hole diameter (EHD), while output variables were density, temperature, strain rate and Zener-Hollomon. The results showed that the numerical analysis was in a good agreement with the experimental method for temperature and density. The most effective parameter in the study was rotational speed (55%). However, the plunge rate exhibited the lowest influence on the process. The highest relative density (0.9961) was obtained at RS = 800 rpm and PR = 20 mm/min. The highest temperature (528°C) and strain rate (38 s−1) were also found at RS = 1000 rpm, PR = 20 mm/min and EHD = 5 mm. Furthermore, the grain size from the center to the outside region of the produced wire was decreased with increasing Zener-Hollomon.

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  1. Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Khomeinishahr, Iran

    Mojtaba Soleimanipour, Reza Abedinzadeh, Ali Heidari & Seyyed Ali Eftekhari

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  1. Mojtaba Soleimanipour
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  2. Reza Abedinzadeh
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  3. Ali Heidari
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  4. Seyyed Ali Eftekhari
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Correspondence to Reza Abedinzadeh.

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Soleimanipour, M., Abedinzadeh, R., Heidari, A. et al. Study on the Friction Stir Extrusion Process of AA1050 Aluminum Alloy Wires Using Numerical Modelling and Taguchi Method. JOM 75, 2909–2923 (2023). https://doi.org/10.1007/s11837-022-05604-6

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