Statistical Analysis of Parameters Affecting the Mechanical Properties of Surface Composite Al7075/Al2O3 Produced by Friction Stir Processing Using Response Surface Methodology

Vahdati, M.; Moradi, M.

doi:10.22044/jsfm.2019.8826.2997

Statistical Analysis of Parameters Affecting the Mechanical Properties of Surface Composite Al7075/Al2O3 Produced by Friction Stir Processing Using Response Surface Methodology

Authors

M. Vahdati ¹
M. Moradi ²

¹ Faculty of Mechanical and Mechatronics Engineering, Shahrood University of Technology, Shahrood, Iran.

² Department of Mechanical Engineering, Malayer University, Malayer, Iran.

10.22044/jsfm.2019.8826.2997

Abstract

In order to improve the properties of aluminum and its alloys, various solutions have been considered, such as: reduction of grain size, addition of alloying elements and composite manufacturing. In this regard, the use of solid-state processes such as friction stir processing (FSP) to create surface composite at temperatures below the melting point is very suitable. Hence, considering the FSP ability as a thermo-mechanical process and its advantages in the production of surface composite, in the present study, the Al7075 surface composites with the use of reinforcing particles (Al2O3) were produced using this process in accordance with the DOE principles. To this end, the response surface methodology (RSM) was selected as the experiment design technique. So, the factors such as: tool rotational speed, tool feed rate, tool shoulder diameter, and reinforcing particle size were identified as the input variables. Then, statistical analysis of variables affecting the mechanical properties of surface composite Al7075/Al2O3 was performed. The obtained results from analysis of variance (ANOVA) and regression analysis of experimental data, confirmed the accuracy of regression equations. Furthermore, it is shown that the linear, interactional and quadratic terms of the input variables are effective on the yield strength and hardness of the composite samples. Also, the tool feed rate and the reinforcing particle size were introduced as the most effective linear factors on the yield strength and hardness of the composite components, respectively.

Keywords

Main Subjects

Industrial Manufacturing

References

[1] Heinz A, Haszler A, Keidel C, Moldenhauer S, Benedictus R, Miller WS (2000) Recent development in aluminium alloys for aerospace applications. Mat Sci Eng A 280 (1): 102-107.

[2] Williams JC, Starke EA (2003) Progress in structural materials for aerospace systems. Acta Mater 51 (19): 5775-5799.

[3] Esmaeili A, Shaeri MH, Talafi Noghani M, Razaghian A (2018) Fatigue behavior of AA7075 aluminium alloy severely deformed by equal channel angular pressing. J Alloy Compd 757: 324-332.

[4] Li JF, Peng ZW, Li CX, Jia ZQ, Chen WJ, Zheng ZQ (2008) Mechanical properties, corrosion behaviors and microstructures of 7075 aluminium alloy with various aging treatments. T Nonferr Metal Soc 18 (4): 755-762.

[5] Shrivastava AK, Singh KK, Dixit AR (2018) Tribological properties of Al 7075 alloy and Al 7075 metal matrix composite reinforced with SiC, sliding under dry, oil lubricated, and inert gas environments. P I Mech Eng J-J Eng 232 (6): 693-698.

[6] Knych T, Mamala A, Ściężor W (2013) Effect of selected alloying elements on aluminium physical properties and its effect on homogenization after casting. Mater Sci Forum 765: 471-475.

[7] Rosochowski A (2005) Processing metals by severe plastic deformation. Sol St Phen 101-102: 13-22.

[8] Baradeswaran A, Elaya Perumal A (2014) Wear and mechanical characteristics of Al 7075/graphite composites. Compos Part B-Eng 56: 472-476.

[9] Tsai MS, Sun PL, Kao PW, Chang CP (2009) Influence of severe plastic deformation on precipitation hardening in an Al−Mg−Si alloy: Microstructure and mechanical properties. Mater Trans 50 (4): 771-775.

[10] Wawer K, Lewandowska M, Wieczorek A, Aifantis EC, Zehetbauer M, Kurzydlowski KJ (2009) Grain refinement in 7475 aluminum alloy via high pressure torsion and hydrostatic extrusion. Kovove Mater 5: 325-332.

[11] Sarkari Khorrami M, Kazeminezhad M, Kokabi AH (2012) Microstructure evolutions after friction stir welding of severely deformed aluminum sheets. Mater Design 40: 364-372.

[12] Thomas WM (1991) Friction stir butt welding. Int Patent No. PCT/GB92/02203.

[13] Ghiasvand A, Hassanifard S (2018) Numerical simulation of FSW and FSSW with pinless tool of AA6061-T6 Al alloy by CEL approach. Journal of Solid and Fluid Mechanics 8 (3): 65-75. (In Persian)

[14] Mishra RS, Mahoney MW, McFadden SX, Mara NA, Mukherjee AK (1999) High strain rate superplasticity in a friction-stir processed 7075 Al alloy. Scripta Mater 41: 163-168.

[15] Mironov S, Sato YS, Kokawa H (2019) Nanocrystalline titanium, Chapter 4: Friction-stir processing. Elsevier, ISBN 9780128145999: 55-69.

[16] Gholami S, Emadoddin E, Tajally M, Borhani E (2015) Friction stir processing of 7075 Al alloy and subsequent aging treatment. T Nonferr Metal Soc 25: 2847-2855.

[17] Abrahams R, Mikhail J, Fasihi P (2019) Effect of friction stir process parameters on the mechanical properties of 5005-H34 and 7075-T651 aluminium alloys. Mat Sci Eng A 751: 363-373.

[18] Rao VR, Ramanaiah N, Sarcar MMM (2014) Fabrication and investigation on properties of TiC reinforced Al7075 metal matrix composites. Appl Mech Mater 592-594: 349-353.

[19] Josyula SK, Narala SKR (2014) A brief review on manufacturing of Al-TiC MMC. Adv Mat Res 980: 62-68.

[20] Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mat Sci Eng R 50 (1-2): 1-78.

[21] Sharma V, Prakash U, Manoj Kumar BV (2015) Surface composites by friction stir processing: A review. J Mater Process Tech 224: 117-134.

[22] Ahmadifard S, Kazemi Sh, Heidarpour A (2015) Fabrication of Al5083/TiO₂ surface composite by friction stir process and investigating its microstructural, mechanical and wear properties. Modares Mechanical Engineering 15 (12): 55-62. (in Persian)

[23] Ahmadifard S, Roknian M, Tinati Seresht T, Kazemi Sh (2016) Fabrication of hybrid nanocomposite Al2024/Gr/ZrO₂ via FSP and evaluation effect role of hybrid ratio in mechanical and wear properties. Modares Mechanical Engineering 16 (6): 119-126. (in Persian)

[24] Arun Babu N, Balu naik B, Ravi B, Rajkumar G (2018) Process parameter optimization for producing AA7075/WC composites by friction stir welding. Mater Today-Proc 5: 18992-18999.

[25] Kumar S, Kumar A, Vanitha C (2019) Corrosion behaviour of Al 7075 /TiC composites processed through friction stir processing. Mater Today-Proc 15: 21-29.

[26] Deore HA, Mishra J, Rao AG, Mehtani H, Hiwarkar VD (2019) Effect of filler material and post process ageing treatment on microstructure, mechanical properties and wear behaviour of friction stir processed AA 7075 surface composites. Surf Coat Tech 374: 52-64.

[27] Jelokhani-Niaraki MR, Mostafa Arab NB, Naffakh-Moosavy H, Ghoreishi M (2016) The systematic parameter optimization in the Nd:YAG laser beam welding of Inconel 625. Int J Adv Manuf Tech 84 (9-12): 2537-2546.

[28] Montgomery DC (2017) Design and analysis of experiments. 9th edn. John Wiley & Sons, ISBN 978-1-119-11347-8.

[29] Myers RH, Montgomery DC, Anderson-Cook CM (2016) Response surface methodology: Process and product optimization using designed experiments. 4th edn. John Wiley & Sons, ISBN 978-1-118 91601-8.

[30] Vahdati M, Mahdavinejad R, Amini S, Moradi M (2015) Statistical analysis and optimization of factors affecting the surface roughness in UVaSPIF process using response surface methodology. J Adv Mat Res 3 (1): 15-28.

[31] Mostafapour A, Kamali H, Moradi M (2017) Friction surfacing of AA7075-T6 deposition on AA2024-T351; Statistical modeling using response surface methodology. Modares Mechanical Engineering 17 (8): 224-230.

[32] Design Expert software, version 11, http://www.statease.com.

[33] http://www.matweb.com

[34] AMSH6088: Heat Treatment of Aluminum Alloys, SAE International, https://www.sae.org.