Parametric Selection and Optimization of Al-Mg-Mn-Zr-Er Alloy Weld Bead Geometry Welded by Laser Using the Aspect Ratio-Based Taguchi Method

Akwaeno Uduak Umoh, Sunday Ayoola Oke, John Rajan, Adeyinka Oluwo, Manasseh Olusegun Oyekeye, Swaminathan Jose, Samuel Bolaji Aderibigbe, Samson Oluwaseun Odudare

Abstract


At present, there is a continuous escalation of labour costs, material costs and other welding-related costs and stabilizing them is challenging. Therefore, optimization of the welding process is essential to stabilize the situation. In this article, an aspect ratio-based Taguchi method is proposed to control the operational performance of the laser welding process while welding the Al-Mg-Mn-Zr-Er alloy sheets. The direct parameters considered are the laser power (LP), welding speed (WS) and welding feed rate (WFR). The aspect ratios analyzed are LP/WS, LP/WFR, WS/LP, WS/WFR, WFR/LP and WFR/WS. The aspect ratios are introduced into the factor/level framework, and the results, transmitted as orthogonal arrays are changed to signal-to-noise ratios. The final results are the delta values, ranks and optimal parametric settings. The principal results indicate that for the LPWS and LP/WFR formulation, the optimal parametric setting is LP/WS1LP/WFR3, which is interpreted as 1.6 kWmin/m LP/WS and 0.35 kWmin/m of LP/WFR. The corresponding delta values are 3.875 and 2.6288 while the positions of 1st and 2nd were obtained by LP/WS and LP/WFR aspect ratios, respectively. It was established that the LP/WS, WS/WFR and WFR/LP are the most important aspect ratios for the laser welding of Al-Mg-Mn-Zr-Er alloy sheets. Therefore, prioritization in resource distribution should be given to these parameters according to their positions. This article serves as a source of information for welding decision-making.

Keywords


Welding; Laser welding; Optimization; Taguchi methods; Selection

Full Text:

PDF

References


Bijivemula N.R., Hema P. & Padmanabhan G. 2022, Experimental investigation on similar and dissimilar alloys of stainless steel joints by laser beam welding, Advances in Materials and Processing Technologies, Vol. 8, No. 1, pp. 13-28. https://doi.org/10.1080/2374068X.2020.1865125

Dey U., Duggirala A., Paul S. & Mitra S., 2023, Prediction of weld geometry in laser welding by numerical simulation & artificial neural networking, Advances in Materials and Processing Technologies, https://doi.org/10.1080/2374068X.2023.2210931

Dong X., Wang G. and Ghaderi M., 2021, Experimental investigation of the effects of laser parameters on the weld bead shape and temperature distribution during dissimilar laser welding of stainless steel 308 and carbon steel St 37, Infrared Physics and Technology, Vol. 116, Article 103774. https://doi.org/10.1016/j.infrared.2021.103774

Guo X., Sahu A.K., Sahu N.K. and Sahu A.K. 2022, A novel integrated computational TRIFMRG approach with grey relational analysis toward parametric evaluation of weld bead geometry of ms-grade: IS 2062, Grey Systems: Theory and Application, Vol. 12 No. 1, pp. 117-141. https://doi.org/10.1108/GS-09-2020-0124

Kumar P. and Sinha A.N. (2019), Effect of average beam power on microstructure and mechanical properties of Nd: YAG laser welding of 304L and st37 steel, World Journal of Engineering, Vol. 16 No. 3, pp. 377-388. https://doi.org/10.1108/WJE-08-2018-0270

Lei X., Huang H. and Wang H., 2015, The fatigue crack propagation of Al-Mg-Mn-Zr alloy with erbium, Advanced Materials Research, Vol. 1120-1121, pp. 1083-1088. https://doi.org/10.4028/www.scientific.net/AMR.1120-1121.1083

Lei Z., Shen J., Wang Q., Chen Y., 2019, Real-time weld geometry prediction based on multi-information using neural network optimized by PCA and GA during thin-plate laser welding, Journal of Manufacturing Processes, Vol. 43, No. 10, pp. 207-217. https://doi.org/10.1016/j.jmapro.2019.05.013

Oji B.C. and Oke S.A. 2020, Optimisation of bottling process using “hard” total quality management elements, The TQM Journal, Vol. 33 No. 2, pp. 473-502. https://doi.org/10.1108/TQM-03-2020-0057

Oke S.A., Adekoya A.A. 2022, Aspect ratio consideration in the optimization of maintenance downtime for handling equipment in a container terminal, Engineering Access, Vol. 8, No. 1, pp. 129-141. https://doi.org/10.14456/mijet.2022.18

Sathiya P., Abdul Jaleel M.Y. and Katherasan D. 2011, Optimizing the weld pool geometry in laser welding of AISI 904 L super austenitic stainless steel using multi‐input/multi‐output grey relational analysis, Multidiscipline Modeling in Materials and Structures, Vol. 7 No. 1, pp. 5-23. https://doi.org/10.1108/15736101111141403

Singh A., Cooper D.E., Blundell N.J., Pratihar D.K. & Gibbons G.J. 2014, Modelling of weld-bead geometry and hardness profile in laser welding of plain carbon steel using neural networks and genetic algorithms, International Journal of Computer Integrated Manufacturing, Vol. 27, No. 7, pp. 656-674. https://doi.org/10.1080/0951192X.2013.834469

Singh S., Yuvaraj N. and Wattal R. 2024, Multicriteria decision-making for optimization of welding parameters in cold metal transfer and pulse metal-inert gas weld bead of AA2099-T86 alloy using CRITIC and ROV methods, Multidiscipline Modeling in Materials and Structures, Vol. 20 No. 3, pp. 466-485. https://doi.org/10.1108/MMMS-07-2023-0250

Wei X., Huang H., Chen Z., Wang W., Li C., Nie Z. 2010, Microstructure and mechanical properties of Al-Mg-Mn-Zr-Er weld joints filled with Al-Mg-Mn-Zr and Al-Mg-Mn-Zr-Er weld wires, Journal of Rare Earths, Vol. 28, No. 4, pp. 627-630. https://doi.org/10.1016/S1002-0721(09)60168-X

Wu H., Wen S.P., Huang H., Wu X.L., Gao K.Y., Wang W. and Nie Z.R., 2016a, Hot deformation behavior and constitutive equation of a new type Al–Zn–Mg–Er–Zr alloy during isothermal compression," Materials Science and Engineering: A, Vol. 651, pp. 415-424. https://doi.org/10.1016/j.msea.2015.10.122

Wu H., Wen S.P., Huang H., Gao K.Y., Wu X.L., Wang W. and Nie Z.R., 2016b, Hot deformation behavior and processing map of a new type Al-Zn-Mg-Er-Zr alloy, Journal of Alloys and Compounds, Vol. 685, pp. 869-880. https://doi.org/10.1016/j.jallcom.2016.06.254

Wu H., Wen S.P., Huang H., Li B.L., Wu X.L., Gao K.Y., Wang W. and Nie Z.R., 2017, Effects of homogenization on precipitation of Al3(Er,Zr) particles and recrystallization behavior in a new type Al-Zn-Mg-Er-Zr alloy, Materials Science and Engineering: A, Vol. 689, pp. 313-322. https://doi.org/10.1016/j.msea.2017.02.071

Yang D., Li X., He D., Nie Z., Huang H., 2012a, Optimization of weld bead geometry in laser welding with filler wire process using Taguchi’s approach, Optics & Laser Technology, Vol. 44, No. 7, pp. 2020-2025. https://doi.org/10.1016/j.optlastec.2012.03.033

Yang D., Li X., He D., Huang H. and Zhang L., 2012b, Study on microstructure and mechanical properties of Al–Mg–Mn–Er alloy joints welded by TIG and laser beam, Materials & Design, vol. 40, pp. 117-123, https://doi.org/10.1016/j.matdes.2012.03.041

Yang D., Li X., He D. and Huang H., 2013, Effect of minor Er and Zr on microstructure and mechanical properties of Al–Mg–Mn alloy (5083) welded joints, Materials Science and Engineering: A, Vol. 561, pp. 226-231. https://doi.org/10.1016/j.msea.2012.11.002

Yang D., Li X., He D., Nie Z.R. and Huang H., 2021, Microstructural and mechanical property characterization of Er modified Al–Mg–Mn alloy tungsten inert gas welds, Materials & Design, Vol. 34, pp. 655-659. https://doi.org/10.1016/j.matdes.2011.05.022

Yang Y., Gao Z. and Cao L., 2018, Identifying optimal process parameters in deep penetration laser welding by adopting Hierarchical-Kriging model, Infrared Physics and Technology, Vol. 92, pp. 443-453, https://doi.org/10.1016/j.infrared.2018.07.006

Zhang Z., Dong S., Wang Y., Zu B., Fang J. and He P., 2015, Microstructure characteristics of thick aluminum alloy plate joints welded by fiber laser, Materials & Design, Vol. 84, pp. 173-177, https://doi.org/10.1016/j.matdes.2015.06.08




DOI: http://dx.doi.org/10.22441/ijiem.v5i2.22749

Refbacks

  • There are currently no refbacks.


Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

IJIEM - Indonesian Journal of Industrial Engineering & Management
Program Pascasarjana Magister Teknik Industri Universitas Mercu Buana
Kampus Menteng - Gedung Tedja Buana, Floor 4th  
Jl. Menteng Raya No. 29  Jakarta Pusat- Indonesia
Tlp.: +62 21 31935454 Fax: +62  21 31934474
http://publikasi.mercubuana.ac.id/index.php/ijiem

Email:  [email protected]

 

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

 

Web Analytics Made Easy - Statcounter View My Stats

The journal is indexed by: