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Optimization of GTAW and FSW Processes

The document outlines the objectives and methodology of a study on fusion welding processes. The main objectives are to optimize process parameters for maximum tensile strength of butt joints welded using GTAW and FSW, measure temperature distribution and residual stress, and characterize the welds. The methodology involves developing thermal models of the welding processes using COMSOL, optimizing parameters using response surface methodology, measuring temperatures and residual stresses experimentally, and validating results with modeling. Characterization of the welds includes tensile testing, fractography, microstructure analysis, and microhardness testing.

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Kamel Fedaoui
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8 views3 pages

Optimization of GTAW and FSW Processes

The document outlines the objectives and methodology of a study on fusion welding processes. The main objectives are to optimize process parameters for maximum tensile strength of butt joints welded using GTAW and FSW, measure temperature distribution and residual stress, and characterize the welds. The methodology involves developing thermal models of the welding processes using COMSOL, optimizing parameters using response surface methodology, measuring temperatures and residual stresses experimentally, and validating results with modeling. Characterization of the welds includes tensile testing, fractography, microstructure analysis, and microhardness testing.

Uploaded by

Kamel Fedaoui
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

CHAPTER-III

OBJECTIVES

3.1 OBJECTIVES OF THE STUDY

The main objectives of the present investigations are:

Optimization of Process Parameters to obtain maximum tensile

strength and fabrication of square butt joints using autogenous GTAW and

FSW process.

Measuring the temperature distribution on the welded samples in the

transverse direction by using Lab VIEW software and validating with

numerical results.

Evaluating the residual stress of welded AA 5059 grade aluminum alloy

joints by using X-ray diffraction method and validating with numerical

results.

Characterization of GTA welding

Viz. Tensile Properties;

Fractography;

Microstructure;

Micro hardness.

Characterization of FS welding

Viz. Tensile Properties;

Fractography;

Microstructure

Micro hardness.
3.2 METHODOLOGY OVERVIEW

To accomplish the research objectives set forth for this study, a

methodology was developed. The methodology was essentially a model-based

approach for optimization of FSW and GTAW processes. The first task was to

develop and validate a thermo mechanical model of FSW and GTAW

processes in consideration of various published papers as discussed in literature

review. The model chosen for this task was the thermo mechanical model

developed for FSW and GTAW of AA 5059 aluminium alloy. The thermo

mechanical model was developed using commercial finite element analysis

program COMSOL. Once developed, the thermo mechanical model was used to

simulate the process. The model was then extrapolated to perform parametric

studies in order to investigate effects of various process parameters on

temperature distribution and residual stress in the work piece.

Meanwhile, process parameters were optimized by using Response

Surface Methodology. During the welding, temperatures were measured by using

Lab-View software. After that, residual stresses were measured by using X-ray

diffraction method. Mechanical and micro structural properties were evaluated. .

Finally, the experimental results were validated by modeling using COMSOL

software for FSW Process. In the case of GTAW process experimental results

were validated by modeling using Ansys software. Figure 3.1 presents an overall

methodology of this research work.

72
Start

Preliminery Investigation of
Aluminium AA 5059 Alloy

Modelling Experimental

GTAW FSW
3D- Thermal analysis of
the FSW & GTAW
No RSM

Temperature Distribution Validation


Temperature
No Measurement

Yes
Residual stress Validation Residual stress
distribution
measurement

Characterization
1. Tensile properties
Yes
2. Fractography
3. Micro structure
4. Micro Hardness
Conclusions

End

Fig. 3.1 Work plan

73

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