Final Year Project(KME-753)

TOPIC- Analysis of Friction Stir Welding using Machine

Learning

JSS ACADEMY OF TECHNICAL EDUCATION NOIDA-201301

• Devesh Kumar Pathak(2000910400047)

• Amit Ahirwar(200091040019)
Mentor- Kapil Panchal Sir • Anshul Sachan(2000910400027)
• Anuratna Dubey(2000910400031)
CONTENT TABLE

 Our Objective
 Design of Experiment
 FSW Setup
 Tool used

 Various Research Paper

 References
OUR OBJECTIVE

 MATERIAL USED IN THIS EXPERIMENT

 THE USE OF ML METHODS TO DIAGNOSE THE

TOOL FAILURE AND TO DETECT THE TOOL
DEFECTS DURING FSW PROCESS
 ABOUT VERTICAL MILLING MACHINE
 ABOUT TOOL USED
 ABOUT BATTERY
What is FRICTION STIR WELDING(FSW)

FSW is a solid-state joining technology in

which the welded materials do not cross their
melting point temperature. This gives FSW
technology superior advantages to weld
difficult to weld materials as well as dissimilar
materials.
In addition, FSW technology has many
technical advantages such as low consumable
tooling costs, low processing time, severe
plastic deformation, low peak temperature, and
excellent-quality joints.
 Design of Experiment

For a 3-factor and 3-level full factorial design, 27 runs are required. This is because
each factor has 3 levels, and all possible combinations of the levels of the factors are
included in the design. This design is also known as a 3^3 design, which implies 27
unique combinations of the three factors at three levels each. Full factorial designs with
three factors at three levels allow for the estimation of the main effects of each factor,
as well as the two-way and three-way interactions between the factors
S.NO Factor 1 Factor 2 Factor 3
Tool Diameter(mm) Tool Rotation(rpm) Feed rate(mm/min)

1 16 900 20
2 16 900 40
3 16 900 60
4 16 1200 20
5 16 1200 40
6 16 1200 60
7 16 1500 20
8 16 1500 40
9 16 1500 60
10 18 900 20
11 18 900 40
12 18 900 60
13 18 1200 20
14 18 1200 40
15 18 1200 60
16 18 1500 20
17 18 1500 40
18 18 1500 60
19 20 900 20
20 20 900 40
21 20 900 60
22 20 1200 20
23 20 1200 40
24 20 1200 60
25 20 1500 20
26 20 1500 40
FSW Setup
TOOL:D3 Tool Steel - High-Carbon, High-
Chromium

HCHCR D3 die steel is available in flat, square and round shape.

D3 Steel having properties of High Carbon 2% and High chromium 12 % tool steel with high
wear resistance.

Heat Treatment:
D3 tool steel requires hardening and tempering to achieve maximum properties.
For maximum accuracy, the parts of D3 tool steel should be stress relieved after
roughing operations. Stress should be relieved at 648°C (1200°F) for one hour
and cooled slowly.

Tempering:
The D3 tool steel should be cooled to room temperature and should be tempered
immediately. The parts should be placed in the tempering furnace and increased
slowly to the desired tempering temperature. Tempering for 1 hour per inch of
thickness is required.
Hardening:
D3 tool steel should be heated properly since it is very sensitive to
overheating and if not heated maximum hardness cannot be
achieved. The work should be directly placed in a furnace
preheated to 954°C (1750°F) and soaked for 20-25 minutes, plus 5
minutes per inch of thickness, and then oil-quenched to harden it.
 Significance of FSW in Manufacturing
The significance of FSW in modern manufacturing is rooted in its ability to provide
strong, high-quality joints with reduced thermal impact, making it a valuable and
versatile process across various industries.
□ Works Well with Tricky Shapes:
□ FSW is like a contortionist. It can handle welding in tight spaces and around
curves, making it perfect for creating complex shapes without breaking a
sweat.
□ Speedy and Consistent:
□ FSW is like the Flash of welding. It's fast and consistent, which means you
can make a lot of products quickly and they'll all be top-notch quality.
□ Eco-Friendly Welding:
□ FSW is like a green superhero. It produces fewer fumes, uses less energy, and
doesn't need a bunch of extra materials. So, it's kinder to the
Why Machine Learning?

Machine learning (ML) offers several advantages in the

context of Friction Stir Welding (FSW), making it a powerful
tool for analysis and optimization.

□ Fault Detection and Quality Assurance

□ Reducing Trial and Error
□ Real-Time Monitoring and Control
□ Tool Wear Prediction
 How Machine Learning works in
FSW
❖ Data Collection:
❖ Gather data related to FSW process parameters (e.g., tool rotation speed, welding
speed, tool tilt angle) and joint properties (e.g., tensile strength, fatigue strength).
❖ Training Data:
❖ Divide the dataset into training and testing sets. The training set is used to train the
Gaussian Process Regression model.
❖ Feature Selection:
❖ Identify relevant features that significantly impact FSW joint properties. These could
include tool parameters, welding conditions, and material properties.
❖ Model Training:
❖ Train the Gaussian Process Regression model using the training data. This involves
learning the underlying relationships between process parameters and joint properties.
❖ Prediction:
❖ Use the trained model to predict joint properties based on new or unseen FSW process
parameters.
❖ Uncertainty Estimation:
❖ Gaussian Process Regression provides not only predictions but also estimates of
uncertainty. This can be valuable in FSW, where the process might have inherent
variability. Understanding the uncertainty in predictions can guide decision-making.
❖ Evaluation:
❖ Evaluate the model's performance on the testing set using appropriate metrics for regression
tasks. Common metrics include mean squared error, R-squared, or others depending on the
specific goals.
❖ Optimization:
❖ Use the trained model for process optimization. This could involve finding the set of
process parameters that maximize or minimize certain joint properties.
 Vertical Milling Machine:

A vertical milling machine is a type of machine tool

used in machining operations, particularly in
metalworking. It operates on the principle of rotary
cutters that remove material from a workpiece by
advancing it in a vertical direction against the
rotating cutter.
 Some key features and components:

1.Spindle: The spindle is a rotating shaft that holds the cutting tool, such as an
end mill or drill bit. It is mounted vertically and can be adjusted in height to
accommodate different workpieces.
2.Table: The workpiece is secured to the table, which can be moved in multiple
directions to position the workpiece relative to the cutting tool. The table may
also have T-slots to allow for clamping various work holding devices.
3.Column: The column is a vertical support that houses the spindle and other
critical components of the milling machine. It provides rigidity and stability to
the machine.
4.Knee: The knee is a vertically adjustable component that supports the saddle
and table. It allows for vertical movement of the table relative to the spindle.
5.Saddle: The saddle is mounted on the knee and can be
moved horizontally along the length of the table. It supports
the table and allows for longitudinal movement during
machining operations.
6.Quill Feed: Some vertical milling machines feature a quill
feed mechanism, which allows for precise vertical movement
of the spindle to drill holes or perform other operations
requiring precise depth control.
7.Controls: Modern vertical milling machines are equipped
with electronic controls that allow operators to adjust spindle
speed, feed rates, and other parameters to optimize machining
performance.
❑ Elsevier BV(2005)

❑ Friction stir welding (FSW) is a relatively

solid-state
new joining process. This joining technique is
energy efficient, environment friendly, and versatile.
In particular, it can be used to join high-strength
aluminum alloys and other metallic alloys that are
hard to weld by conventional fusion welding. FSW is
considered to be the most significant development in
metal joining in a decade. Recently, friction stir
processing (FSP) was developed for microstructural
modification of metallic materials.
❑ Elsheikh, A. H. (2023)

❑ The use of ML to predict the mechanical and

metallurgical properties of FSW joints in which ML
methods are used to figure out the relationship
between the control factors of the welding
process and the process responses.
❑ The use of ML methods to real-time control
of
FSW process to enhance the quality of the FSW
joints.
❑ The use of ML methods to diagnose the tool
failure and to detect the tool defects during FSW
process.
 ❑ Mohammad Syahid
Mohd Isa(2021)

Al and Cu are employed in various industrial applications due to their high

plasticity, thermal conductivity electrical conductivity and characteristics. By
effectively joining dissimilar Al and Cu, the unique properties of composite
formed by these metals can be adequately addressed. Friction stir
welding(FSW), an energy-efficient solid-state welding process is capable
of joining dissimilar metals, has enormous potential in the future of various
industries. This present work comprehensively summarises all pertinent
topics related to Al and
Cu FSW, such as FSW process parameters, microstructural
characterization, mechanical properties, and electrical
characteristics of Al-Cu joints produced by FSW.
❑ Anandan, B., & Manikandan, M. (2021)
Friction stir welding (FSW) is a solid-state joining process that produces joints without melting
and recasting. This process gains attention for joining similar and dissimilar metals like the
Aluminium alloy 7050 and 2014A. FSW provides very low peak temperature and heat
distribution compared to the conventional joining techniques. In the FSW technique, the normal
working temperatures range from 200 to 550 °C based on its process parameters. The
aluminium alloys 7050 and 2014A are precipitant hardened alloys, and their precipitates
dissolve at temperatures above 350 °C. It leads to a degradation of the mechanical properties of
the weldment. Predicting peak temperature (PT) is the major phenomenon in getting good
quality weld joints with respect to the FSW process parameters. This study deals with the
prediction of peak temperature using machine learning (ML) approaches in various regression
analysis methods like linear regression (LR), polynomial regression (PR), support vector
regression (SVR), decision tree regression (DTR), and random forest regression (RFR). As a
result, the RFR analysis is strongly suitable to predict the peak temperature in the FSW
process. A tool rotation speed of 1000 rpm ensured the peak temperature of less than 300 °C
with good appearance, proper material mixing, and the absence of defects.
❑ Matitopanum, S., Pitakaso, R., Sethanan, K. (2023)

❑ This research aims to develop ensemble machine-

learning
methods for forecasting the ultimate tensile strength (UTS)
of friction stir welding (FSW). The substance utilized in the
experiment was a mixture of aluminum alloys
AA5083 and
AA5061. An ensemble machine learning model was created
to predict the UTS of the friction stir-welded seam, utilizing
11 FSW parameters as input factors and the UTS
as a
response variable. The proposed approach used the Gaussian
process regression (GPR) and the support vector
machine
 • Gite(2019, January 1)

Process parameters such as

“rotational speed, welding traverse speed, tilt
angle, axial force, probe
and shoulder profile”, etc.must be
optimized for successful
implementation of FSW.
Squillace, A. (2009, March
1) The effect of processing parameters on
mechanical and microstructural properties of
AA6082 joints produced by friction stir welding
was analysed in the present study. Different
welded specimens were produced by employing a
fixed rotating speed of 1600rpm and by varying
welding speeds from 40 to 460mm/min.
Saikumar, A. (2023, March 1)
 The majority of comparable research studies concluded that
important factors, such as welding speed, rotational speed, plunge
depth, spindle torque, shoulder design, base material, pin profile
and tool type have a significant impact on the weldability of the
aluminium joint when using the FSW method. FSW parameters are
selected as tool speed(1200rpm, 1400rpm and 1600rpm), welding
speed (200mm/min, 300mm/min and 400mm/min) and axial force
(4 kN, 6 kN and 8 kN). For the tensile strength analysis, the axial
force is highly influenced and the maximum tensile strength of 175
MPa is attained.
M. F. (2023, September 1)
 Process parameters have a great influence on the quality
of the weld joints. In particular, basic process variables
such as tool design, rotational speed, welding speed,
and axial force were reviewed in this study. By
optimizing these process parameters, weld strength can
be increased by minimizing welding defects. In addition,
the effects of the FSW method on mechanical properties
such as hardness, tensile, and fatigue behaviors were
discussed.
 CONCLUSION :
 Friction stir welding (FSW) is a widely used joining process in various industries.The
full factorial design method has been used to study the effects of multiple parameters on
the FSW outcomes. The machine learning regression processes, such as Gaussian
process regression (GPR), support vector machine (SVM), and multi-linear regression
(MLR), can be used to predict the ultimate tensile strength (UTS) of FSW joints . The
studies have shown that the optimized parameters employed in these investigations can
lead to predictable microstructural and mechanical behavior expected for defect-free
FSW welds. The results of these studies demonstrate the potential of machine learning
regression processes and full factorial design methods to optimize FSW and improve
the quality of the welds.
 References:
❑ Mishra, R. S., & Ma, Z. (2005, August 1). Friction stir welding and processing. Materials Science and
Engineering: R: Reports; Elsevier BV. https://doi.org/10.1016/j.mser.2005.07.001

❑ Verma, S., Gupta, M., & Misra, J. P. (2018, January 1). Performance evaluation of friction stir welding
using machine learning approaches. MethodsX; Elsevier BV. https://doi.org/10.1016/j.mex.2018.09.002

❑ Elsheikh, A. H. (2023, May 1). Applications of machine learning in friction stir welding: Prediction of joint
properties, real-time control and tool failure diagnosis. Engineering Applications of Artificial Intelligence;
Elsevier BV. https://doi.org/10.1016/j.engappai.2023.105961

❑ Anandan, B., & Manikandan, M. (2022, October 1). Machine learning approach for predicting the peak
temperature of dissimilar AA7050-AA2014A friction stir welding butt joint using various regression
models. Materials Letters; Elsevier BV. https://doi.org/10.1016/j.matlet.2022.132879

❑ Matitopanum, S., Pitakaso, R., Sethanan, K., Srichok, T., & Chokanat, P. (2023, January 27). Prediction of
the Ultimate Tensile Strength (UTS) of Asymmetric Friction Stir Welding Using Ensemble Machine Learning
Methods. Processes; Multidisciplinary Digital Publishing Institute. https://doi.org/10.3390/pr11020391
 References:

❑ Anandan, B., & Manikandan, M. (2023, March 1). Machine learning approach with various regression models
for predicting the ultimate tensile strength of the friction stir welded AA 2050-T8 joints by the K-Fold
cross-validation method. Materials Today Communications; Elsevier
BV. https://doi.org/10.1016/j.mtcomm.2022.105286

❑ Ahmed, M. M. Z., Seleman, M. M. E. S., Fydrych, D., & Çam, G. (2023, April 8). Friction Stir Welding of
Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review .
Materials; Multidisciplinary Digital Publishing Institute. https://doi.org/10.3390/ma16082971

❑ B. London, M. Mahoney, B. Bingel, M. Calabrese, D. Waldron Proceedings of the Third International Symposium
on Friction Stir Welding, Kobe, Japan, 27–28 September (2001)
❑ Tashkandi, M. A. (2017, June 1). Lap Joints of 6061 Al Alloys by Friction Stir Welding. IOP Conference Series.
https://doi.org/10.1088/1757-899x/205/1/012005
 References:
 Cavaliere, P., De Santis, A., Panella, F., & Squillace, A. (2009, March 1). Effect of welding parameters on
mechanical and microstructural properties of dissimilar AA6082–AA2024 joints produced by friction stir welding.
Materials in Engineering. https://doi.org/10.1016/j.matdes.2008.05.044
 Gite, R. A., Loharkar, P. K., & Shimpi, R. (2019, January 1). Friction stir welding parameters and application: A
review. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2019.07.613
 Saravanan, R., Malladi, A., Amuthan, T., Aneesh, V., Jerin, A., Anbuchezhiyan, G., & Saikumar, A. (2023, March 1).
Mechanical characterization of friction stir welded dissimilar aluminium alloy using Taguchi approach. Materials
Today: Proceedings. https://doi.org/10.1016/j.matpr.2023.03.278
 Kılıç, S., Öztürk, F., & Demi̇ rdöğen, M. F. (2023, September 1). A comprehensive literature review on friction stir
welding: process parameters, joint integrity, and mechanical properties. Journal of Engineering Research.
https://doi.org/10.1016/j.jer.2023.09.005
 Simoncini, M., Costa, A., Fichera, S., & Forcellese, A. (2020, December 31). Experimental Analysis and
Optimization to Maximize Ultimate Tensile Strength and Ultimate Elongation of Friction Stir Welded AA6082
Aluminum Alloy. Metals. https://doi.org/10.3390/met11010069