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Myśliwiec P, Kubit A, Szawara P. Optimization of 2024-T3 Aluminum Alloy Friction Stir Welding Using Random Forest, XGBoost, and MLP Machine Learning Techniques. MATERIALS (BASEL, SWITZERLAND) 2024; 17:1452. [PMID: 38611968 PMCID: PMC11012866 DOI: 10.3390/ma17071452] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/04/2024] [Revised: 03/18/2024] [Accepted: 03/20/2024] [Indexed: 04/14/2024]
Abstract
This study optimized friction stir welding (FSW) parameters for 1.6 mm thick 2024T3 aluminum alloy sheets. A 3 × 3 factorial design was employed to explore tool rotation speeds (1100 to 1300 rpm) and welding speeds (140 to 180 mm/min). Static tensile tests revealed the joints' maximum strength at 87% relative to the base material. Hyperparameter optimization was conducted for machine learning (ML) models, including random forest and XGBoost, and multilayer perceptron artificial neural network (MLP-ANN) models, using grid search. Welding parameter optimization and extrapolation were then carried out, with final strength predictions analyzed using response surface methodology (RSM). The ML models achieved over 98% accuracy in parameter regression, demonstrating significant effectiveness in FSW process enhancement. Experimentally validated, optimized parameters resulted in an FSW joint efficiency of 93% relative to the base material. This outcome highlights the critical role of advanced analytical techniques in improving welding quality and efficiency.
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Affiliation(s)
- Piotr Myśliwiec
- Department of Materials Forming and Processing, Rzeszow University of Technology, al. Powst. Warszawy 8, 35-959 Rzeszów, Poland
| | - Andrzej Kubit
- Department of Manufacturing and Production Engineering, Rzeszow University of Technology, al. Powst. Warszawy 8, 35-959 Rzeszów, Poland;
| | - Paulina Szawara
- Doctoral School of Engineering and Technical Sciences, Rzeszow University of Technology, al. Powst. Warszawy 12, 35-959 Rzeszów, Poland;
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Essa ARS, Eldersy RIA, Ahmed MMZ, Abd El-Aty A, Alamry A, Alzahrani B, El-Nikhaily AE, Habba MIA. Modeling and Experimental Investigation of the Impact of the Hemispherical Tool on Heat Generation and Tensile Properties of Dissimilar Friction Stir Welded AA5083 and AA7075 Al Alloys. MATERIALS (BASEL, SWITZERLAND) 2024; 17:433. [PMID: 38255601 PMCID: PMC10817553 DOI: 10.3390/ma17020433] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/16/2023] [Revised: 01/09/2024] [Accepted: 01/11/2024] [Indexed: 01/24/2024]
Abstract
This study investigated the effect of a hemispherical friction stir welding (FSW) tool on the heat generation and mechanical properties of dissimilar butt welded AA5083 and AA7075 alloys. FSW was performed on the dissimilar aluminum alloys AA5083-H111 and AA7075-T6 using welding speeds of 25, 50, and 75 mm/min. The tool rotation rate was kept constant at 500 rpm. An analytical model was developed to calculate heat generation and temperature distribution during the FSW process utilizing a hemispherical tool. The experimental results were compared to the calculated data. The latter confirms the accuracy of the analytical model, demonstrating a high degree of agreement. Sound FSW dissimilar joints were achieved at welding speeds of 50 and 25 mm/min. Meanwhile, joints created at a welding speed of 75 mm/min exhibited a tunnel-like defect, which can be attributed to the minimal heat generated at this particular welding speed. At a lower welding speed of 25 mm/min, a higher tensile strength of the dissimilar FSWed joints AA5083 and AA7075 was achieved with a joint efficiency of over 97%.
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Affiliation(s)
- Ahmed R. S. Essa
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
- Faculty of Engineering, King Salman International University, El Tor 45615, Egypt
| | - Ramy I. A. Eldersy
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
| | - Mohamed M. Z. Ahmed
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
- Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43211, Egypt
| | - Ali Abd El-Aty
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
- Mechanical Engineering Department, Faculty of Engineering, Helwan University, Cairo 11795, Egypt
| | - Ali Alamry
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
| | - Bandar Alzahrani
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
| | - Ahmed E. El-Nikhaily
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
| | - Mohamed I. A. Habba
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
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Chyła K, Gaska K, Gronba-Chyła A, Generowicz A, Grąz K, Ciuła J. Advanced Analytical Methods of the Analysis of Friction Stir Welding Process (FSW) of Aluminum Sheets Used in the Automotive Industry. MATERIALS (BASEL, SWITZERLAND) 2023; 16:5116. [PMID: 37512391 PMCID: PMC10384280 DOI: 10.3390/ma16145116] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/14/2023] [Revised: 07/12/2023] [Accepted: 07/17/2023] [Indexed: 07/30/2023]
Abstract
The paper provides general information on selected methods of joining aluminum sheets. The main focus is on the strength of the friction stir welding connection and the energy consumption of the process. The practical part of the study used aluminum alloy 2024-T3, the most commonly used alloy in the automotive industry. The study consisted of the FSW welding of two pieces of overlapping sheet metal, using different process parameters. The thickness of the sheet used was 1 mm. After the welding was completed, the test specimens were broken on a testing machine. During the tests, the appropriate process parameters were selected at which the weld showed the highest strength. The effect of implementing the FSW process should be to increase the efficiency of sheet-metal joining. It should also result in a reduction in the energy intensity of the process, which will translate into the lower production cost of the final product. Strength tests were carried out on eighteen samples of joined sheets. The best results were obtained at a feed rate of 100 (mm/min) and a rotational speed of 900 (rpm). It can also be seen that friction welding is an efficient and low-emission way of joining metals. Through the analysis, it can be concluded that in order to perform one meter of satisfactory welding, CO2 emissions will be approximately 310 g. These are calculations based on data published by the National Balancing and Emissions Management Centre from 2019. Analyzing the 2019 data from the Society of Automobile Manufacturers, it is safe to say that the potential for implementing the FSW method in the automotive industry is huge.
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Affiliation(s)
- Krzysztof Chyła
- Faculty of Energy and Environmental Engineering, Silesian University of Technology, 44-100 Gliwice, Poland
| | - Krzysztof Gaska
- Faculty of Energy and Environmental Engineering, Silesian University of Technology, 44-100 Gliwice, Poland
| | - Anna Gronba-Chyła
- Faculty of Natural and Technical Sciences, John Paul II Catholic University of Lublin, ul. Konstantynów 1 H, 20-708 Lublin, Poland
| | - Agnieszka Generowicz
- Department of Environmental Technologies, Cracow University of Technology, ul. Warszawska 24, 31-155 Cracow, Poland
| | - Katarzyna Grąz
- Faculty of Natural and Technical Sciences, John Paul II Catholic University of Lublin, ul. Konstantynów 1 H, 20-708 Lublin, Poland
| | - Józef Ciuła
- Faculty of Engineering Sciences, State University of Applied Sciences in Nowy Sącz, Zamenhofa 1A, 33-300 Nowy Sącz, Poland
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