Optimization of Bobbin Tool Friction Stir Processing Parameters of AA1050 Using Response Surface Methodology
Ibrahim Albaijan1, Mohamed M Z Ahmed1,2, Mohamed M El-Sayed Seleman2
1Mechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 16273, Saudi Arabia.
Materials (Basel, Switzerland)
|October 14, 2022
Summary
This study developed a statistical model for bobbin tool friction stir processing (BT-FSP) of aluminum alloy. Cylindrical pin geometry at 200 mm/min travel speed optimizes mechanical properties and surface finish.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Processes
Background:
- Friction stir processing (FSP) is a solid-state joining and material modification technique.
- Bobbin tool FSP (BT-FSP) offers advantages in processing efficiency and surface finish.
- Optimizing BT-FSP parameters is crucial for enhancing mechanical properties of aluminum alloys.
Purpose of the Study:
- To develop a statistical model for BT-FSP of AA1050 aluminum alloy.
- To investigate the influence of tool travel speed and pin geometry on processing outcomes.
- To optimize BT-FSP parameters for improved mechanical properties and reduced surface roughness.
Main Methods:
- Response Surface Method (RSM) with Face Central Composite Design (FCCD).
- Analysis of tool travel speeds (100-300 mm/min) and pin geometries (triangle, square, cylindrical).
- Mathematical modeling to predict machine torque, processing zone temperature, surface roughness, hardness, and ultimate tensile strength (UTS).
Main Results:
- The developed statistical model accurately predicts BT-FSP responses with >95% confidence.
- Pin geometry was identified as the most influential parameter.
- Optimal parameters for highest hardness and UTS, with lowest roughness and torque, are 200 mm/min travel speed and cylindrical pin geometry.
Conclusions:
- The statistical model effectively guides BT-FSP parameter optimization for AA1050.
- Cylindrical pin geometry at 200 mm/min travel speed yields superior mechanical properties and surface quality.
- Further research can explore a wider range of parameters and alloy compositions.
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