Optimization of electron beam welding parameters to improve corrosion resistance of AA2219 aluminium alloy

Authors

  • B Rajnaveen Department of Mechanical Engineering, Andhra University, Visakhapatnam, India-530003
  • D Balaji Naik Department of Mechanical Engineering, Universal College of Eng. & Tech, Guntur India-52200
  • G Rambabu Department of Mechanical Engineering, Andhra University, Visakhapatnam, India-530003
  • K Srinivasa Rao Department of Mechanical Engineering, Andhra University, Visakhapatnam, India-530003

Keywords:

AA2219 alloy, corrosion resistance, electron beam welding, response surface methodology, travel speed, voltage, welding current

Abstract

Aluminium alloys are ideal for the production of lightweight structures. These alloys also have a high strength-to-weight ratio and superior corrosion resistance. Electron beam welding (EBW) is widely used for the joining of AA2219 al alloy, which is a high-energy beam welding technology that melts the workpiece surface and forms the joint using a focused beam of electrons. The Taguchi method of experimental design was applied in this study to examine the effect of input parameters on corrosion resistance. Input parameters like welding current, travel speed and voltage are used as controlling parameters to create the experimental design, and each parameter is divided into three levels. Therefore, an L9 orthogonal array was used for the experimental design. Potentio dynamic polarization tests were conducted for all designed experimental arrays to determine the pitting potential (corrosion resistance) in millivolts. An Analysis of Variance (ANOVA) technique was used to determine the governing parameters of the process. The findings of ANOVA revealed that voltage is the most influential parameter, followed by welding current and travel speed. Further, response surface methodology (RSM) has been used to form the mathematical model of the AA2219 aluminium alloy. This mathematical model helped in finding the predicted value of pitting potential. The optimized parameters of the AA2219 aluminium alloy were obtained by using RSM. The outcomes of RSM indicate that maximum corrosion resistance is achieved when welding current, travel speed and voltage are chosen as 50 mA, 1200 mm/min and 53 kV respectively.

References

Anderson, V. L., & McLean, R. A. (2018). Design of experiments: a realistic approach. US: CRC Press. https://doi.org/10.1201/9781315141039

Banerjee, S., Bhadra, R., & Gogoi, S. (2020). Investigating Weldability in Microalloyed Al Alloys. In Advances in Mechanical Engineering (pp. 271-279). Singapore: Springer. https://doi.org/10.1007/978-981-15-0124-1_25

Brennecke, M. W. (1965). Electron beam welded heavy gage aluminum alloy 2219. Retrieved form https://ntrs.nasa.gov/citations/19650033282

Chen, Y. B., Miao, Y. G., Li, L. Q., & Lin, W. U. (2009). Joint performance of laser-TIG double-side welded 5A06 aluminum alloy. Transactions of Nonferrous Metals Society of China, 19(1), 26-31. https://doi.org/10.1016/S1003-6326(08)60223-X

Dursun, T., & Soutis, C. (2014). Recent developments in advanced aircraft aluminium alloys. Materials & Design (1980-2015), 56, 862-871. https://doi.org/10.1016/j.matdes.2013.12.002

Esmailzadeh, S., Aliofkhazraei, M., & Sarlak, H. (2018). Interpretation of cyclic potentiodynamic polarization test results for study of corrosion behavior of metals: a review. Protection of metals and physical chemistry of surfaces, 54(5), 976-989. https://doi.org/10.1134/S207020511805026X

Grbović, A., Burzić, Z., & Perković, S. (2022). Influence of Corrosion on Parameters of Fracture Mechanics of Aluminium Alloys 2024-T351 and 7075-T651. Tehnički vjesnik, 29(1), 239-245. https://doi.org/10.17559/TV-20210425222503

Heinz, A., Haszler, A., Keidel, C., Moldenhauer, S., Benedictus, R., & Miller, W. S. (2000). Recent development in aluminium alloys for aerospace applications. Materials Science and Engineering: A, 280(1), 102-107. https://doi.org/10.1016/S0921-5093(99)00674-7

Jebaraj, A. V., Aditya, K. V. V., Kumar, T. S., Ajaykumar, L., & Deepak, C. R. (2020). Mechanical and corrosion behaviour of aluminum alloy 5083 and its weldment for marine applications. Materials Today: Proceedings, 22, 1470-1478. https://doi.org/10.1016/j.matpr.2020.01.505

Koona, B., Ramana, V. V., Prasad, C., & Vikas, K. S. R. (2021). Comparison of microstructure and corrosion behaviour of AA2014 electron beam and friction stir welds. Materials Today: Proceedings, 52, 1615-1621. https://doi.org/10.1016/j.matpr.2021.11.272

Kumar, R., & Singh, N. K. (2022). Modelling and Simulation on Behaviours of Aluminium Alloys. In Advances in Mechanical and Materials Technology (pp. 703-711). Springer, Singapore. https://doi.org/10.1007/978-981-16-2794-1_62

Majeed, T., Mehta, Y., & Siddiquee, A. N. (2021). Precipitation-dependent corrosion analysis of heat treatable aluminum alloys via friction stir welding, a review. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 235(24), 7600-7626. https://doi.org/10.1177/09544062211003609

Mastanaiah, P., Sharma, A., & Reddy, G. M. (2018). Process parameters-weld bead geometry interactions and their influence on mechanical properties: A case of dissimilar aluminium alloy electron beam welds. Defence technology, 14(2), 137-150. https://doi.org/10.1016/j.dt.2018.01.003

Montgomery, D. C. (2017). Design and analysis of experiments. New Jersey, US: John wiley & sons.

Naik, D. B., Rao, C. V., Rao, K. S., Reddy, G. M., & Rambabu, G. (2019). Optimization of friction stir welding parameters to improve corrosion resistance and hardness of AA2219 aluminum alloy welds. Materials Today: Proceedings, 15, 76-83. https://doi.org/10.1016/j.matpr.2019.05.027

Nair, B. S., Phanikumar, G., Prasad Rao, K., & Sinha, P. P. (2007). Improvement of mechanical properties of gas tungsten arc and electron beam welded AA2219 (Al–6 wt-% Cu) alloy. Science and Technology of Welding and Joining, 12(7), 579-585. https://doi.org/10.1179/174329307X227210

Rambabu, P. P. N. K. V., Eswara Prasad, N., Kutumbarao, V. V., & Wanhill, R. J. H. (2017). Aluminium alloys for aerospace applications. Aerospace materials and material technologies, 29-52. https://doi.org/10.1007/978-981-10-2134-3_2

Rao, S. K., Reddy, G. M., Rao, K. S., Kamaraj, M., & Rao, K. P. (2005). Reasons for superior mechanical and corrosion properties of 2219 aluminum alloy electron beam welds. Materials characterization, 55(4-5), 345-354. https://doi.org/10.1016/j.matchar.2005.07.006

Rekab, K., & Shaikh, M. (2005). Statistical design of experiments with engineering applications (Vol. 252). Boca Raton, FL: Taylor & Francis.

Sobih, M., Elseddig, Z., Almazy, K., & Sallam, M. (2016). Experimental Evaluation and Characterization of Electron Beam Welding of 2219 AL-Alloy. Indian Journal of Materials Science, 2016. https://doi.org/10.1155/2016/5671532

Sriba, A., & Vogt, J. B. (2021). Galvanic Coupling Effect on Pitting Corrosion of 316L Austenitic Stainless Steel Welded Joints. Metals and Materials International, 27(12), 5258-5267. https://doi.org/10.1007/s12540-020-00789-4

Srinivasa Rao, K., & Prasad Rao, K. (2006). Corrosion resistance of AA2219 aluminium alloy: electrochemical polarisation and impedance study. Materials science and technology, 22(1), 97-104. https://doi.org/10.1179/174328406X79405

Trishul, M. A., & Panda, B. (2020). A Review on the Challenges in Welding of Aluminium AA2219 Alloy. Advances in Lightweight Materials and Structures, 8, 663-671. https://doi.org/10.1007/978-981-15-7827-4_68

Trzil, J. P., & Hood, D. W. (1969). Electron Beam Welding 2219-Aluminum Alloy for Pressure Vessel Applications. Welding Journal, 48(9), S395.

Verma, R. P., & Lila, M. K. (2021). A short review on aluminium alloys and welding in structural applications. Materials Today: Proceedings, 46, 10687-10691. https://doi.org/10.1016/j.matpr.2021.01.447

Wang, J., Liu, Z., Bai, S., Cao, J., Zhao, J., Luo, L., & Li, J. (2021). Microstructure evolution and mechanical properties of the electron-beam welded joints of cast Al–Cu–Mg–Ag alloy. Materials Science and Engineering: A, 801, 140363. https://doi.org/10.1016/j.msea.2020.140363

Xu, W., & Liu, J. (2009). Microstructure and pitting corrosion of friction stir welded joints in 2219-O aluminum alloy thick plate. Corrosion Science, 51(11), 2743-2751. https://doi.org/10.1016/j.corsci.2009.07.004

Yang, M., Lu, J., Chen, J., Li, Y., Liu, Y., & Yang, H. (2020). Effect of welding speed on microstructure and corrosion resistance of Al–Li alloy weld joint. Materials and Corrosion, 71(2), 300-308. https://doi.org/10.1002/maco.201911068

Downloads

Published

2022-12-26

How to Cite

B Rajnaveen, D Balaji Naik, G Rambabu, & K Srinivasa Rao. (2022). Optimization of electron beam welding parameters to improve corrosion resistance of AA2219 aluminium alloy. Journal of Current Science and Technology, 12(3), 417–427. Retrieved from https://ph04.tci-thaijo.org/index.php/JCST/article/view/255

Issue

Section

Research Article