MP 110550

MATERIALS TESTING FOR JOINING TECHNOLOGIES 1

Optimization of Friction Welding

Parameters for AISI 904L Super
Austenitic Stainless Steel by
Evolutionary Computational
Techniques
K. Balamurugan, Thanjavur, Friction welding is a type of solid state welding and it plays an impor-
Jiju V Elies, P. Sathiya, tant role in joining metal surfaces with the help of frictional heat accom-
Tiruchirappalli, and A. Naveen panied with high force. Optimization of process parameters of friction
Sait Pudukkottai, Tamil Nadu, welding is important for all types of materials. Optimization of input
India parameters of friction welding also plays a very significant role in deter-
mining the quality of a weld joint. Purpose of this study is to optimize
the welding process parameters in friction welding of AISI 904L super
austenitic stainless steel by using regression analysis and evolutionary
Article Information algorithms. This study is to determine optimimum welding process
Correspondance Adress parameters of friction welding with the help of Genetic Algorithm (GA)
????? and Simulated Annealing (SA). This study also explains how to obtain
?????
????? near optimum welding conditions over a wide search range by conduct-
Keywords ing a relatively smaller number of experiments. Results of these evolu-
Keyword, Keyword, Keyword tionary computational techniques were compared with experimental
results. Finally, anoptimization parameter is obtained for the maximum
fatigue life and the minimum welding time.

Friction welding is a solid state joining pro-
cess that produces coalescence by harness-
ing the heat developed through controlled
rubbing of the faying surfaces. Due to the
heat, the material reaches a softened state,
at which the plasticized material begins to
form layers that intervene with one another
and results in a good quality weld. To pro-
duce the good quality joint it is important to
set up the proper welding process parame-
ters. The welding process is a multi-input
and multi-output process in which joints
are closely associated with welding param-
eters. Therefore, identifying the suitable
combinations of process input parameters
to produce the desired output require many
experiments [1] thereby making this pro-
cess time consuming and costly.
Moreover the main objective of this
study is to maximize the fatigue life and
minimize the welding time. To achieve the
objective, regression modeling is used to
map the input/output relationships of the
joining process with the help of the experi-
mental data. Genetic Algorithm (GA) and
Simulated Annealing (SA) are used to
search for the near optimal welding param-
eters.
Literature Review
There have been many studies on screen-
ing experiments, modeling and optimiza-
tion for welding processes. However, there
are a few techniques to move the experi-
mental region to near optimal welding con-
dition. Factorial design was employed as a
guide for optimization of process parame-
ters by Kim et al [2]. Murti and Sundaresan
[3] employed statistical experimental de-
signs to optimize process parameters.
Three commonly used dissimilar metal
combinations were used and only a fair
agreement was obtained between predicted
and actual strengths for joints.
The selection of process parameters for
obtaining optimal weld pool geometry in
the tungsten inert gas welding of the stain-
less steel was carried out. A modified tagu-
chi method was adopted to analyze the ef-
fect of each welding process parameters on
the weld pool geometry, and to determine
the process parameters with optimal weld
pool geometry [4]. Gunaraj and Murugan

56 (2014) 3  © Carl Hanser Verlag, München  Materials Testing

2 MATERIALS TESTING FOR JOINING TECHNOLOGIES
[5] used Response Surface Methodology
(RSM) by designing a four factor, five level
central composite rotatable design matrix
with full replication for planning, conduc-
tion, execution and development of mathe-
matical models. These are useful not only
for selecting optimum process parameters
but also for achieving the desired quality
and process optimization. Neural network
and multiple regression methods were
used to understand the relationships be-
tween process parameters and top-bead
width, and to predict the process parame-
ters on bead width in robotic gas metal arc
welding process [6].
Polar coordinate model was established
to characterize the weld pool geometry of
gas metal arc welding. They also proposed
a neural network to identify the parame-
ters in real time. By using pulsed laser
elimination, a clear image of the weld pool
was captured. The developed image pro-
cessing algorithm extracted the boundary
of the weld pool in the real time. It played a
vital role in determining the optimized
welding process parameters and to obtain
the desired weld bead geometry in gas
metal arc welding [7]. Kim and Rhee opti-
mized the arc welding process parameters
using GA [8]. Tarang et al. [9] had em-
ployed Neural network techniques to ob-
tain the relationship between welding pro-
cess parameters and weld pool geometry in
TIG welding process. Simulated annealing
(SA) was then applied to the network for
searching the process parameters with op-
timal weld pool geometry. A three-dimen-
sional steady state thermal model of fric-
tion stir welding of AA2024-T3 plates was
simulated. The effect of the tool rotation on
the temperature distribution was consid-
ered. This thermal model was integrated
with the non-dominated sorting genetic al-
gorithm (NSGA-II) to solve a common man-
ufacturing problem having conflicting ob-
jectives, i. e., maximization of production
rate and tool lifetime. The multiple trade-
off solutions were then investigated to un-
veil any design rule which had a strong
potential in industrial use [10].
The genetic algorithm tools are widely
used in the area of material science and its
related fields of science and technology,
GAs are routinely used for materials mod-
eling and design, for optimization of mate-
rial properties and the method is also use-
ful in organizing the material or device
production at the industrial scale related to
the material science fields [11].
A new bi-objective genetic programming
technique was developed, i. e. a single ob-
jective procedure which subsequently
switches to bi-objective evolution to work
out a Pareto-tradeoff between model com-
plexity and accuracy. For example a highly
noisy industrial data were collected from
an operational iron making blast furnace.
This method was pitted against an Evolu-
tionary Neural Network has been devel-
oped earlier by the authors. The bi-objec-
tive genetic programming procedure was
found to produce very competitive results
for this complex modeling problem [12].
Material. Super austenitic stainless
steels are particularly interesting because
they are cheaper than austenitic stainless
steel and expensive nickel based super al-
loys. Super austenitic stainless steels are
highly useful when high corrosion proper-
ties are required at moderate high tempera-
ture [13]. It is well known that the major
drawback of ordinary austenitic stainless
steel is its moderate resistance to pitting
corrosion, which is particularly evident
when such alloys are in contact with a hal-
ide-containing corrosive medium. The in-
crease in molybdenum contents in nitrogen
can dramatically improve the pitting resist-
ance. This effect can be pointed out by the
pitting resistance equivalent number [14],
which depends on chromium as well as the
molybdenum and nitrogen content.
It is noted that only few researchers
have investigated in the past the effect of
shielding gases on super austenitic stain-
less steel. Specific information on the fric-
tion welding of AISI 904 L super austenitic
stainless steel has not yet been fully estab-
lished. The present investigation is con-
cerned with the optimization of the process
parameters like rotational speed, friction
pressure, upset pressure and burn-off
length in friction welding process with the
objectives of maximum fatigue life and
minimum welding time. Moreover the
main objective of this study is to maximize
the fatigue life and minimize the welding
time. To achieve this objective, regression
Elements Si Mn P S
Composition 0.374 1.522 0.018 0.004
Table 1. Chemical composition of the base material (wt.-%)
Parameters
Rotational Speed (rpm)
Table 2. Welding Friction Pressure FP (MPa)
parameters
Upset Pressure UP (MPa)
Burn-off length (mm)
modeling is used to map the input/output
relationships of the joining process with
the help of the experimental data. Genetic
Algorithm (GA) and Simulated Annealing
(SA) are used to search the near optimal
welding parameters.
Experimental
A continuous drive friction welding ma-
chine (KUKA, Germany) with a maximum
150 kN load was used for welding. Austen-
itic stainless steel (AISI 904L) specimens
of size 16 mm diameters and a length of
160 mm were used as parent materials in
this study. The chemical composition of the
specimen material is presented in Table 1.
The working ranges for all selected pa-
rameters were fixed by conducting trial
runs. This was carried out by varying one
of the parameters while keeping the rest of
them at constant values and inspecting the
bead for a smooth appearance without any
visible defect. The upper and lower limits
with different levels of the identified pro-
cess parameters in friction welding are
given in Table 2.
The present problem is a four factor
three level problem. The Design of experi-
ments (DOE) was done by Taguchi method
using Minitab-15 statistical software. The
design matrix chosen to conduct the ex-
periment was a Taguchi L27 orthogonal ar-
ray. It consisted of 27 sets of coded condi-
tions. Thus the 27 experimental runs al-
lowed the estimation of linear, quadratic
and two-way interactive effects of the pro-
cess parameters. The fatigue test experi-
ments were carried out under uniaxial ten-
sile loading condition using servo hydrau-
lic fatigue testing machine (Make:
INSTRON, UK; Model: 8801) under con-
stant amplitude loading. The fatigue test
Procedures were followed by the as per the
ASTM E647-04 standard. The test results
obtained from the experiments are tabu-
lated in Table 3. The objective function was
Cr Ni Mo C Cu
19.893 25.557 4.124 0.018 1.65
Level 1 Level 2 Level 3
1000 1500 2000
40 80 120
125 150 175
2 4 6
56 (2014) 3
 MATERIALS TESTING FOR JOINING TECHNOLOGIES 3

formulated by regression modeling using Figure 2. In fatigue life, some abnormal val- ‘FL’ and ‘T’ given below shows the fit and
Minitab-15 software. Theoretical optimiza- ues were creeping in between. This is be- adequacy of the regression model.
tion was carried out in order to maximize cause of the high values (no. of cycles in
fatigue life and to minimize the welding the range of 100 k to 300 k) that we are Optimization using
time by non-traditional optimization tech- dealing with. But in the case of time, both GA and SA
niques like GA and SA, using optimization the trends were in good agreement.
toolboxes in Matlab R2010a software. Normal Probability Plot. This was gen- Genetic Algorithm. GA was first proposed
erated while creating the regression model by Holland [15]. GA is always used to get
Regression Modeling in MINITAB. Figure 3 and Figure 4 are the solution for different problems in an ef-
helpful to understand, explain/prove the fit fective manner by generation via its sys-
The general response function represent- of the model. The normal probability of the tematic operators, which provide improve-
ing any of the output parameters can be
expressed as Y = f (S, F, U, B). The mathe-
matical model to establish the relation- No. S (rpm) F (MPa) U(MPa) B (mm) T (sec) FL (no. of cycles)
ships between input and output parame- 1 1000 40 125 2 62.780 135 000
ters were developed using Minitab-15 soft-
2 1000 40 150 4 70.590 184 000
ware at a confidence level of 95 %, based on
3 1000 40 175 6 81.050 300 000
the experimental data collected from Ta-
ble 3. Fatigue life (FL) and Welding time 4 1200 80 125 4 24.410 175 000
(T) were expressed in the form of a non- 5 1200 80 150 6 33.500 235 000
linear function of process parameters, 6 1200 80 175 2 58.920 325 000
namely rotational speed (S), friction pres-
7 1500 120 125 6 20.020 200 000
sure (F), upset pressure (U) and burn-off
length (B). The following regression equa- 8 1500 120 150 2 15.020 302 000
tions have thus been obtained: 9 1500 120 175 4 17.250 256 000
10 1500 40 125 2 19.643 205 000
Fatigue Life:
11 1500 40 150 4 11.917 272 000
FL = -1304649 + 824 S + 4399 F + 8814 U +
9526 B - 0.0903 S2 + 2.14 F2 - 2.8 U2 - 12 1500 40 175 6 89.280 255 000
1772 B2 - 0.594 SF - 3.29 SU - 1.8 SB - 13 1500 80 125 4 36.040 220 000
23.2 FU - 3 FB (1) 14 1500 80 150 6 36.640 250 000
15 1500 80 175 2 35.640 285 000
The coefficient of correlation for the model
was found to be R-Sq = 75.8 % (R-Sq(adj) = 16 1500 120 125 6 17.000 310 000
51.6 %) which is acceptable. The decreased 17 1500 120 150 2 16.010 275 000
value of R-Sq is due to the wide range of 18 1500 120 175 4 15.630 290 000
values obtained in the experiment.
19 2000 40 125 2 10.043 221 000

Welding Time: 20 2000 40 150 4 12.863 245 000

T=3 79 - 0.049 S - 0.18 F - 3.77 U - 6.6 B + 21 2000 40 175 6 20.907 233 000
0.000005 S2 - 0.00427 F2 + 0.0158 U2 + 22 2000 80 125 4 31.890 277 000
1.40 B2 + 0.000823 SF – 0.000443 SU +
23 2000 80 150 6 28.540 197 000
0.00300 SB – 0.00203 FU –
0.0960 FB (2) 24 2000 80 175 2 24.470 231 000
25 2000 120 125 6 20.500 238 000
The coefficient of correlation for the model 26 2000 120 150 2 20.520 250 000
was found to be R-Sq = 82.6 % R-Sq(adj) =
27 2000 120 175 4 20.190 227 000
65.3 % which is well within the acceptable
limits. Table 3. Experimental results
Adequacy of the Regression Model. The
comparison between the experimental and
predicted values (for the 25 experiments)
is given below. The graph says that the re-
gression model predicts the values to a
good extent. Here, we generated a graph
with the experimental and predicted val- Figure 1. Fatigue life:
Experimental vs
ues for the 27 experiments and the values
predicted data
obtained by regression model enabled to
study whether both are aligning or not.
Graphical representation of regression
model checking was shown in Figure 1 and

56 (2014) 3
4 MATERIALS TESTING FOR JOINING TECHNOLOGIES

ments and variety in the solution popula-

tion [16, 17]. GA is a heuristic technique
inspired by the natural biological evolu-
tionary process comprising of proper selec-
tion of crossover, mutation, etc. The evolu-
Figure 2. Welding time:
Experimental vs tion starts with a population of randomly
predicted data generated individuals in first generation.
In each generation, the fitness of every in-
dividual in the population is evaluated,
compared with the best value, and modi-
fied (recombined and possibly randomly
mutated), if required, to form a new popu-
lation. The new population is then used in
the next iteration of the algorithm. The al-
gorithm terminates, when either a maxi-
mum number of generations has been pro-
duced or a satisfactory fitness level has
been reached for the population
The genetic algorithm (GA) tool box in
MATLAB R2010a was used to solve the op-
timization problem. Inside the experimen-
tal space, the GA choose randomly, the ini-
tial welding setup, i. e., the parameters
values of the first experiment within the
input parameter range i. e. speed (1000-
2000 rpm), friction pressure (40-120 MPa),
upset pressure (125-175 Mpa) and burn-off
length (2-4 mm). After it (the first exp.)
was done, its response characteristics were
Figure 3. Normal probability plot: Response FL measured and fed into the GA. Then, based
on the previous information, the algorithm
chooses another setup; carry out the ex-
perimentation and its data were again fed
into the algorithm. This process was con-
tinued until the optimum was found, i. e.,
until the objective function reached its
minimum. In the GA, a population size of
100, uniform selection function with a
cross over fraction of 0.08, uniform muta-
tion function with a mutation rate of 0.02
and single point crossover function were
selected as the optimization toolbox param-
eters. The maximum number of genera-
tions was set to 500 and function toler-
ances of 1 × 10-6 were selected as stopping
criteria. The objectives maximization of fa-
tigue life and minimization of welding time
were given weights in the ratio (0.7 : 0.1)
respectively. The optimal values of process
parameters obtained by the GA are shown
in Table 4.
Simulated Annealing (SA). SA is a nu-
merical optimization technique based on
Figure 4. Normal Probability plot: Response T
the principles of thermodynamics. SA is
motivated by an analogy to annealing in
solids. This algorithm simulated the cooling
of material in a heat bath. This is a process
Algorithm S (rpm) F (MPa) U (MPa) B (mm) T (sec) FL (no. of cycles) known as annealing. If you heat a solid past
GA 1195 119.96 167 2.9 14.14 302370 melting point and then cool it, the struc-
tural properties of the solid depend on the
Table 4. Optimal parameter values by GA rate of cooling. If the liquid is cooled slowly

56 (2014) 3

enough (annealed), large crystals will be
formed. However, if the liquid is cooled
quickly (quenched) the crystals will con-
tain imperfections. The algorithm simulates
the cooling process by gradually lowering
the temperature of the system until it con-
verges to a steady frozen state.
The tool box in SA was used to solve the
optimization problem presented. Boltz-
mann function with a reannealing interval
of 100 and exponential temperature update
function with initial temperature of 100
were selected as the SA toolbox parameters
for the present problem as they were giv-
ing the best results. The weights were as-
signed to the two responses namely fatigue
life and welding time in the ratio (0.7 : 0.3)
respectively. The optimal values of process
parameters obtained by the SA are shown
in Table 5.
Results and Discussion
Many studies are related to modeling and
optimization of different welding processes
and other manufacturing processes. Some
of these studies [18-20] considered only a
single output as the response, and a math-
ematical model was developed which could
accurately predict the output for a particu-
lar combination of input parameters. This
modeling was done either based on re-
sponse surface methodology or intelligent
methods like artificial neural network.
Even though some researchers [21-23] had
considered multi objective problems, they
had followed a conventional approach in
which the mathematical models were de-
veloped for each objective separately, and
these models were combined into a single
model by using weighted sum method. A
major problem here was to choose the
proper weight combination for each objec-
Algorithm S (rpm) F (MPa) U (MPa)
SA 1274 118 166.78
Table 5. Optimal parameter values obtained by SA
Algorithm S (rpm) F (Mpa) U (MPa)
Predicted 1195 119.96
GA Experimental 1200 120
% error
Predicted 1274 118
SA Experimental 1250 118
% error
Table 6. Confirmation test results
56 (2014) 3
MATERIALS TESTING FOR JOINING TECHNOLOGIES
tive. Another drawback in this conven-
tional approach was that the optimization
will results in a single solution which may
be dominated towards a particular objec-
tive. Abdullah et al. [24] have discussed the
different approaches in multi objective op-
timization using genetic algorithm (GA).
They suggested that a reasonable solution
to a multi objective problem was to investi-
gate a set of solutions, each of which would
satisfy the objectives at an acceptable level
without being dominated by any other so-
lution. In the present study multi objective
optimization was done using multi objec-
tive GA which resulted in a set of solution
rather than a single solution. The confirma-
tion test was carried out on the feasible so-
lution (near optimum values of GA & SA
from Table 4 & 5) as shown in Table 6. The
same experimental set up for the experi-
ment was used for conducting the confir-
mation tests. Table 6 reflects the satisfac-
tory results of confirmatory experiment.
From the results it is evident that the feasi-
ble solution had come closer to the optimal
values predicted by optimization and the
error was negligible. The percentage error
in the confirmation experiments was quite
high. This could be because of experimen-
tal errors. We can conduct multiple experi-
ments to verify the same. Ideally this
should be less than 2.
Conclusions
In this study, the optimization of the pro-
cess parameters in friction welding pro-
cess of AISI 904L austenitic stainless steel
was carried out using evolutionary algo-
rithms, GA and SA. Initial experiments
were performed as per the design of exper-
iments by Taguchi L27 orthogonal array.
Using the results, regression analysis was
B (mm) T (sec) FL (no. of cycles)
2.87 15.41 299780
B (mm) T (sec) FL (no. of cycles)
167 2.9 14.14 302370
167 2.9 14.93 300980
0.06 0.004
166.78 2.87 15.41 299780
167 2.9 14.10 301620
0.085 0.006
5
conducted with the help of Minitab-15 soft-
ware to determine input-output relation-
ships of the process parameters. The math-
ematical model was then optimized with
the objectives of maximum fatigue life and
minimum welding time. The results were
verified using confirmation tests. The mul-
tiple objectives were optimized satisfacto-
rily by the GA and SA algorithms and the
percentage error was found to be negligibly
small. Future research in future might lead
to the possibility of conducting numerical
experiments which will justify the stability
of the results with the variation of both
crossover and mutation probabilities.
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Abstract
Optimierung von Reibschweißparamtern für einen AISI 904L superaus-
tenitischen Stahl mit evolutionären Computertechniken. Reibschwei-
ßen ist eine Art des Schweißens im festen Zustand und es hat eine große
Bedeutung für die Verbindung von Metalloberflächen mit Hilfe der Reib-
wärme begleitet von großen Kräften. Die Optimierung der Prozessparame-
ter beim Reibschweißen ist für alle Materialarten wichtig. Die Optimierung
der Inputparameter beim Reibschweißen ist bedeutend für die Bestim-
mung der Schweißnahtqualität. Der Zweck der diesem Beitrag zugrunde
liegenden Studie besteht darin, die Prozessparameter beim Reibschweißen
eines AISI 904L superaustenitischen Stahles mittels Regressionsanalyse
und evolutionären Algorithmen zu optimieren. Diese Studie zielt darauf
ab, die optimalen Parameter mit Hilfe eines Genetischen Algorithmus´
und simulierten Anlassens zu bestimmen. Sie erklärt außerdem, wie na-
hezu optimale Schweißbedingungen über einen großen Suchbereich unter
Durchführung einer relativ kleinen Zahl von Experimenten zu erhalten.
Die Ergebnisse dieser evolutionären Computertechniken wurden mit expe-
rimentellen Resultaten verglichen. Schließlich wurde ein Optimierungspa-
rameter für eine maximale Lebensdauer unter Ermüdungsbeanspruchung
und einer minimalen Schweißzeit gefunden.
Bibliography toren Bios fehlen ••• Autoren Bios fehlen •••
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DOI 10.3139/120.110550 ••• Autoren Bios fehlen ••• Autoren Bios fe-
Materials Testing hlen ••• Autoren Bios fehlen ••• Autoren Bios
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