Faculty Publications
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Item Experimental assessment of FSW process to join AA6061/Rutile composite and parametric optimization using TGRA(IOP Publishing Ltd, 2021) Prabhu B, S.R.; Shettigar, A.; Herbert, M.A.; Rao, S.S.Present study is focused on investigating the effect of various friction stir welding (FSW) process variables on AA6061/Rutile composites welding quality. FSWof composites was performed considering tool geometry (Tg), welding speed (Ws) and rotational speed (Ns) as ideal parameters for multi-response optimization. Experiments were designed based on the L9 orthogonal array. Analysis of variance (ANOVA) was utilized to evaluate the effects of these welding process variables on output responses namely hardness and ultimate tensile strength (UTS). Main effects plots were drawn to found out the optimal levels of these process parameters. Multi-response optimization of the welding process has been performed using Taguchi's grey relational analysis (TGRA). Analysis revealed that welding speed of 90mmmin-1, a tool with a square pin, and rotational speed of 1000 rpm produced an FSWjoint with excellent mechanical properties. Microstructure analysis revealed that refinement in the grain structure and redistribution of reinforced particles helped in improved joint strength. © 2021 IOP Publishing Ltd.Item Optimization of FSW process parameters for maximum UTS of AA6061/rutile composites using Taguchi technique(Sharif University of Technology, 2022) Prabhu B, S.R.; Shettigar, A.; Herbert, M.A.; Rao, S.S.In the friction stir welding process, preferred joint property is vastly reliant on the selection of optimal welding conditions. The present study aims to use the Taguchi technique to find the optimal process conditions for achieving superior Ultimate Tensile Strength (UTS) in friction stir welded Aluminum Matrix Composite (AMC) joints. AMCs reinforced with rutile particles which have a potential application in the aerospace, automotive, and marine industries are used in the present work. Taguchi parametric design technique was used to identify the effect of rotational speed, tool traverse speed, and tool geometry on joint strength. Taguchi approach confined the optimum level of process variables and these variables were optimized. The investigation showed that the parameters within the selected value range will seriously affect the output. The predicted value of the output response was 155.48 MPa, which was validated by further experiments using the optimum process variables. Analysis Of Variance (ANOVA) results indicated that the UTS of the composite joint is mainly affected by the tool traverse speed followed by rotational speed, and tool geometry. The microstructural study unveiled that grain size is dependent on process variables and finer grains offer better joint properties. © 2022 Sharif University of Technology. All rights reserved.Item Optimization of process parameters for friction stir processing (FSP) of AA8090/boron carbide surface composites(Springer Science and Business Media Deutschland GmbH, 2024) Adiga, K.; Herbert, M.A.; Rao, S.S.; Shettigar, A.K.Friction Stir Processing (FSP) is an innovative and promising technique for microstructure refinement, material property enhancement, and surface composite production. The current study describes the fabrication of AA8090/boron carbide surface composites (SCs) by FSP. Experimental studies were conducted by varying the FSP parameters, specifically the rotational speed (800–1400 rpm), traverse speed (25–75 mm/min), and groove width (1–1.8 mm). Ultimate Tensile Strength (UTS), Surface Roughness (SR), and Percentage Elongation (El) were used as response measures. Experiments were planned based on the central composite design (CCD) of Response Surface Methodology (RSM) and a mathematical relationship between the input parameters and UTS, SR and El, and were obtained by RSM. The model adequacy was tested using analysis of variance (ANOVA). The models enabled the examination of individual and interaction effects of input parameters on the UTS, SR, and El of the produced SCs. AA8090/boron carbide SC strength was optimal of 366 MPa at 800 rpm, 75 mm/min, and 1.8 mm and optimal 21.13% elongation at 1400 rpm, 25 mm/min, and 1 mm. A smoother surface with 0.82-μm roughness was optimal at 1400 rpm, 25 mm/min, and 1.2 mm. The present study uses the FSP method to synthesize near-net-shaped SCs without further machining by systematically selecting process parameters. The study shows that the increase in rotational speed during AA8090/boron carbide SC fabrication produces composites with a good surface finish, lower UTS, and good ductility. However, the increase in the other two parameters, namely, traverse speed and groove width, produces low ductile composites with rougher surfaces and higher strengths. Graphical abstract: (Figure presented.) © International Institute of Welding 2024.