Development of Empirical Relationships for Prediction of Wear Properties of AA6092/B<sub>4</sub>C Aluminum Matrix Composites Produced Using Friction Stir Welding

Jamaludeen, Umar Mohamed

doi:10.1590/1980-5373-MR-2024-0468

Thumbnail

Figure 1 The fabricated stir cast AA6092/ B₄C composite plate.

Thumbnail

Figure 2 Dimensions of Friction Stir Welding tool.

Thumbnail

Figure 3 Photograph showing typical FSW experimental set up and friction stir welded plate.

Thumbnail

Figure 4 Perturbation plot (impact of process parameters on the W).

Thumbnail

Figure 5 (a) 2D contour plot, (b) 3D contour plot (effect of TRS and WS on W of FSW joint.

Thumbnail

Figure 6 (a) 2D contour plot, (b) 3D contour plot (effect of TRS and AL on W of FSW joint).

Thumbnail

Figure 7 (a) 2D contour plot, (b) 3D contour plot (effect of TRS and C on W of FSW joint).

Thumbnail

Figure 8 (a) 2D contour plot, (b) 3D contour plot (effect of AL and WS on W of FSW joint).

Thumbnail

Figure 9 (a) 2D contour plot, (b) 3D contour plot (effect of W and WS on W of FSW joint).

Thumbnail

Figure 10 (a) 2D contour plot, (b) 3D contour plot (effect of W and AL on W of FSW joint).

Thumbnail

Figure 11 Perturbation plot (effect of process parameters on the WR).

Thumbnail

Figure 12 (a) 2D contour plot, (b) 3D contour plot (effect of TRS and WS on WR of FSW joint).

Thumbnail

Figure 13 (a) 2D contour plot, (b) 3D contour plot (effect of TRS and AL on WR of FSW joint).

Thumbnail

Figure 14 (a) 2D contour plot, (b) 3D contour plot (effect of C and TRS on WR of FSW joint).

Thumbnail

Figure 15 (a) 2D contour plot, (b) 3D contour plot (effect of AL and WS on WR of FSW joint).

Thumbnail

Figure 16 (a) 2D contour plot, (b) 3D contour plot (effect of C and WS on WR of FSW joint).

Thumbnail

Figure 17 (a) 2D contour plot, (b) 3D contour plot (effect of C and AL on WR of FSW joint).

Thumbnail

Figure 18 SEM images of AA6092 -10% B₄C composite: (a) before FSW process and (b) after FSW process.

Thumbnail

Figure 19 SEM images of worn surface of the FSW AA6092-B₄C composite containing: (a) 2.5% B₄C; (b) 5% B₄C; (c) 7.5% B₄C; and (d) 10% B₄C.

Thumbnail

Table 1 The chemical composition of AA6092 alloy matrix.

Thumbnail

Table 2 Wear Rate and Wear Resistance of AA6092 composites.

Thumbnail

Table 3 Chemical composition of High Carbon High Chromium steel.

Thumbnail

Table 4 Process parameters and its levels.

Thumbnail

Table 5 Design matrix and experimental results.

Thumbnail

Table 6 ANOVA results for Wear Rate (W).

Thumbnail

Table 7 ANOVA results for Wear Resistance (WR).

Thumbnail

Table 8 Optimization criteria used in this work.

Thumbnail

Table 9 Optimized FSW process parameters and responses predicted by design expert. software.

Thumbnail

Table 10 Experimental and predicted values for thirty-one runs.

Thumbnail

Table 11 Validation of test results.

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

Element	Mg	Si	Fe	Mn	Cu	Cr	Zn	Ti	Al
Wt. %	1.2	0.4	0.3	0.15	0.7	0.15	0.25	0.15	Balance

Sample No		1	2	3	4	5
% of compositions	AA6092	100	95	90	85	80
% of compositions	B₄C	0	2.5	5	7.5	10
Wear Rate (1 x 10 ^-5) mm³/m)		538	482	463	432	445
Wear Resistance (m/ mm³)		186	207	216	231	225

Element	C	Mn	Si	Co	Cr	Mo	V	P	Ni	Cu	S
Wt. %	1.4-1.6	0.6	0.6	1	11-13	0.7-1.2	1.1	0.03	0.3	0.25	0.03

S. No.	Process Parameter	Notation	Unit	Levels
S. No.	Process Parameter	Notation	Unit	-2	-1	0	1	2
1.	Tool Rotational Speed	TRS	rpm	1000	1075	1150	1225	1300
2.	Welding Speed	WS	mm/min	30	40	50	60	70
3.	Axial Load	AL	kN	4	5	6	7	8
4.	% of B₄C	C	Wt.%	0	2.5	5	7.5	10

Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)	% of B₄C (Wt.%)	Wear Rate (1 x10^-5 mm³/m)	Wear Resistance (m/mm³)	Relative Wear Rate
R1	1075	40	5	2.5	425	235	0.88
R2	1225	40	5	2.5	406	246	0.84
R3	1075	60	5	2.5	412	243	0.85
R4	1225	60	5	2.5	437	229	0.91
R5	1075	40	7	2.5	405	247	0.84
R6	1225	40	7	2.5	429	233	0.89
R7	1075	60	7	2.5	419	239	0.87
R8	1225	60	7	2.5	432	231	0.90
R9	1075	40	5	7.5	278	360	0.64
R10	1225	40	5	7.5	273	366	0.63
R11	1075	60	5	7.5	279	358	0.65
R12	1225	60	5	7.5	287	348	0.66
R13	1075	40	7	7.5	262	382	0.61
R14	1225	40	7	7.5	284	352	0.66
R15	1075	60	7	7.5	257	389	0.59
R16	1225	60	7	7.5	286	350	0.66
R17	1000	50	6	5	365	274	0.79
R18	1300	50	6	5	397	252	0.86
R19	1150	30	6	5	386	259	0.83
R20	1150	70	6	5	362	276	0.78
R21	1150	50	4	5	364	275	0.79
R22	1150	50	8	5	379	264	0.82
R23	1150	50	6	0	429	233	0.80
R24	1150	50	6	10	170	588	0.38
R25	1150	50	6	5	328	305	0.71
R26	1150	50	6	5	343	292	0.74
R27	1150	50	6	5	323	310	0.70
R28	1150	50	6	5	346	289	0.75
R29	1150	50	6	5	340	294	0.73
R30	1150	50	6	5	316	316	0.68
R31	1150	50	6	5	326	307	0.70

Source	Sum of Squares	df	Mean Square	F-value	p-value
Model	1.297E+05	14	e9266.24	59.98	< 0.0001	significant
A-Tool Rotational Speed	224.02	1	224.02	1.45	0.2460
B-Welding Speed	29.17	1	29.17	0.1888	0.6697
C-Axial Load	50.38	1	50.38	0.3261	0.5759
D-% of B₄C	19269.14	1	19269.14	124.72	< 0.0001
AB	175.56	1	175.56	1.14	0.3023
AC	390.06	1	390.06	2.52	0.1316
AD	7.56	1	7.56	0.0489	0.8277
BC	22.56	1	22.56	0.1460	0.7074
BD	33.06	1	33.06	0.2140	0.6499
CD	68.06	1	68.06	0.4405	0.5163
A²	3419.95	1	3419.95	22.14	0.0002
B²	2412.99	1	2412.99	15.62	0.0011
C²	2095.81	1	2095.81	13.57	0.0020
D²	2547.72	1	2547.72	16.49	0.0009
Residual	2472.01	16	154.50
Lack of Fit	1702.58	10	170.26	1.33	0.3786	not significant
Pure Error	769.43	6	128.24
Cor Total	1.322E+05	30

Source	Sum of Squares	df	Mean Square	F-value	p-value
Model	1.550E+05	14	11074.19	35.62	< 0.0001	significant
A-Tool Rotational Speed	487.30	1	487.30	1.57	0.2286
B-Welding Speed	1.80	1	1.80	0.0058	0.9402
C-Axial Load	121.65	1	121.65	0.3913	0.5405
D-% of B₄C	53211.08	1	53211.08	171.15	< 0.0001
AB	125.06	1	125.06	0.4023	0.5349
AC	438.27	1	438.27	1.41	0.2524
AD	147.35	1	147.35	0.4739	0.5010
BC	36.91	1	36.91	0.1187	0.7349
BD	2.05	1	2.05	0.0066	0.9363
CD	113.81	1	113.81	0.3661	0.5536
A²	2892.32	1	2892.32	9.30	0.0076
B²	2252.88	1	2252.88	7.25	0.0160
C²	2050.34	1	2050.34	6.59	0.0206
D²	20656.99	1	20656.99	66.44	< 0.0001
Residual	4974.44	16	310.90
Lack of Fit	4337.32	10	433.73	4.08	0.0493	significant
Pure Error	637.12	6	106.19
Cor Total	1.600E+05	30

Process Parameters / Responses	Goal	Minimum Limit	Maximum Limit	Importance
Tool Rotational Speed	is in range	1075	1225	3
Welding Speed	is in range	40	60	3
Axial Load	is in range	5	7	3
Wt.% B₄C	is in range	5	15	3
Wear Rate (1 x10^-5)	minimize	437	170	5
Wear Resistance	maximize	229	588	5

Tool rotational speed (rpm)	Welding Speed (mm/min)	Axial load (kN)	Wt.% of B₄C	Wear Rate (1 x10^-5 mm³/m)	Wear Resistance (m/mm³)
1150	50	6	10	154.21	551.97

Run	Wear Rate (1 x10^-5 mm³/m)			Wear Resistance (m/mm³)
Run	Experimental Value	Predicted Value	Error in %	Experimental Value	Predicted Value	Error in %
R1	425	418	1.65	235	230	2.13
R2	406	413	-1.72	246	240	2.44
R3	412	419	-1.70	243	249	-2.47
R4	437	429	1.83	229	235	-2.62
R5	405	415	-2.47	247	255	-3.24
R6	429	437	-1.86	233	239	-2.58
R7	419	426	-1.67	239	234	2.09
R8	432	426	1.39	231	225	2.60
R9	278	284	-2.16	360	369	-2.50
R10	273	285	-4.40	366	372	-1.64
R11	279	286	-2.51	358	350	2.23
R12	287	283	1.39	348	356	-2.30
R13	262	275	-4.96	382	378	1.05
R14	284	289	-1.76	352	360	-2.27
R15	257	267	-3.89	389	380	2.31
R16	286	293	-2.45	350	356	-1.71
R17	365	373	-2.19	274	282	-2.92
R18	397	405	-2.02	252	260	-3.17
R19	386	393	-1.81	259	265	-2.32
R20	362	369	-1.93	276	284	-2.90
R21	364	373	-2.47	275	269	2.18
R22	379	386	-1.85	264	257	2.65
R23	429	436	-1.63	233	239	-2.58
R24	170	174	-2.16	588	572	2.72
R25	328	335	-2.13	305	313	-2.62
R26	343	349	-1.75	292	296	-1.37
R27	323	330	-2.17	310	317	-2.26
R28	346	352	-1.73	289	294	-1.73
R29	340	351	-3.24	294	286	2.72
R30	316	324	-2.53	316	322	-1.90
R31	326	318	2.45	307	317	-3.26

Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)	Wt.% of B₄C	W (1 x10^-5 mm³/m)		Error in %	WR (m/mm³)		Error in %
Run	Tool Rotational Speed (rpm)	Welding Speed (mm/min)	Axial Load (kN)	Wt.% of B₄C	Actual value	Predicted value	Error in %	Actual value	Predicted value	Error in %
R1	1150	50	6	10	162	154.21	4.81	566	551.97	2.47
R2	1150	50	6	10	160	154.21	3.62	567	551.97	2.65
R3	1150	50	6	10	163	154.21	5.39	565	551.97	2.31

\begin{array}{l} W (\times 10^{- 5}), m m^{3} / m = 4092.8719 - (5.01634 \times T R S) - \\ (13.2693 \times W S) - (168.0863 \times A L) - (9.2393 \times C) + \\ (0.0044 \times T R S \times W S) + (0.0658 \times T R S \times A L) + (0.0037 \times T R S \times C) - \\ (0.1187 \times W S \times A L) - (0.0575 \times W S \times C) - (0.8250 \times A L \times C) + \\ (0.0019 \times T R S^{2}) + (0.0919 \times W S^{2}) + (8.5610 \times A L^{2}) - (1.5102 \times C^{2}) \end{array}

\begin{array}{l} W R, m / m m^{3} = - 3246.5073 + (4.7202 \times T R S) + (12.1811 \times W S) + \\ (169.5570 \times A L) - (2.9673 \times C) - (0.0037 \times T R S \times W S) - \\ (0.0698 \times T R S \times A L) - (0.0162 \times T R S \times C) + (0.1519 \times W S \times A L) + \\ (0.0144 \times W S \times C) + (1.0668 \times A L \times C) - (0.0018 \times T R S^{2}) - \\ (0.0888 \times W S^{2}) - (8.4676 \times A L^{2}) + (4.3003 \times C^{2}) \end{array}

Development of Empirical Relationships for Prediction of Wear Properties of AA6092/B₄C Aluminum Matrix Composites Produced Using Friction Stir Welding

Abstract

Development of Empirical Relationships for Prediction of Wear Properties of AA6092/B4C Aluminum Matrix Composites Produced Using Friction Stir Welding

Abstract

Development of Empirical Relationships for Prediction of Wear Properties of AA6092/B₄C Aluminum Matrix Composites Produced Using Friction Stir Welding