Search results for: Fuzzy Logic Speed Controller

Authors: Kashyap L. Mokariya, Varsha A. Shah, Makarand M. Lokhande

Abstract:

As the current status and growth of Indian automobile industry is remarkable, transportation sectors are the main concern in terms of energy security and climate change. Due to rising demand of fuel and its dependency on foreign countries that affects the GDP of nation, suggests that penetration of electrical vehicle will increase in near future. So in this context analysis is done if the 10 percent of conventional vehicles including cars, three wheelers and two wheelers becomes electrical vehicles in near future which is also a part of Nations Electric Mobility Mission Plan then the saving which improves the nation’s economy is analyzed in detail. Whether the Indian electricity grid is capable of taking this load with current generation and demand all over the country is also analyzed in detail. Current situation of Indian grid is analyzed and how the gap between generation and demand can be reduced is discussed in terms of increasing generation capacity and energy conservation measures. Electrical energy conservation measures in Industry and especially in rural areas have been analyzed to improve performance of Indian electricity grid in context of electrical vehicle penetration in near future. Author was a part of Vishvakarma yojna in which energy losses were measured in 255 villages of Gujarat and solutions were suggested to mitigate them and corresponding reports was submitted to the authorities of Gujarat government.

Keywords: Vehicle penetration, feasibility, Energy conservation, future grid, Energy security, Automatic pf controller.

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Authors: J. Jezierski, K. Janerka

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The results of the two-phase gas-solid jet in pneumatic powder injection process analysis were presented in the paper. The researches were conducted on model set-up with high speed camera jet movement recording. Then the recorded material was analyzed to estimate main particles movement parameters. The values obtained from this direct measurement were compared to those calculated with the use of the well-known formulas for the two-phase flows (pneumatic conveying). Moreover, they were compared to experimental results previously achieved by authors. The analysis led to conclusions which to some extent changed the assumptions used even by authors, regarding the two-phase jet in pneumatic powder injection process. Additionally, the visual analysis of the recorded clips supplied data to make a more complete evaluation of the jet behavior in the lance outlet than before.

Keywords: injection lance, liquid metal, powder injection, slip velocity, two-phase jet

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Authors: Alireza Rezaei, Fatemeh Baharifard, Kourosh Parand

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In this paper we improve the quasilinearization method by barycentric Lagrange interpolation because of its numerical stability and computation speed to achieve a stable semi analytical solution. Then we applied the improved method for solving the Fin problem which is a nonlinear equation that occurs in the heat transferring. In the quasilinearization approach the nonlinear differential equation is treated by approximating the nonlinear terms by a sequence of linear expressions. The modified QLM is iterative but not perturbative and gives stable semi analytical solutions to nonlinear problems without depending on the existence of a smallness parameter. Comparison with some numerical solutions shows that the present solution is applicable.

Keywords: Quasilinearization method, Barycentric lagrange interpolation, nonlinear ODE, fin problem, heat transfer.

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Authors: Marinka Baghdasaryan, Tigran Mnoyan

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The pertinence of modeling the moment of resistance generated by the ore-grinding mill is substantiated. Based on the ranking of technological indices obtained in the result of the survey among the specialists of several beneficiating plants, the factors determining the level of the moment of resistance generated by the mill are revealed. A priori diagram of the ranks is obtained in which the factors are arranged in the descending order of the impact degree on the level of the moment. The obtained model of the moment of resistance shows the technological character of the operation modes of the ore-grinding mill and can be used for improving the operation modes of the system motor-mill and preventing the abnormal mode of the drive synchronous motor.

Keywords: Model, abnormal mode, mill, correlation, moment of resistance, rotational speed.

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Authors: Martin Kendra, Jaroslav Mašek, Juraj Čamaj, Matej Babin

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The railway transport is considered as a one of the most environmentally friendly mode of transport. With future prediction of increasing of freight transport there are lines facing problems with demanded capacity. Increase of the track capacity could be achieved by infrastructure constructive adjustments. The contribution shows how the travel time can be minimized and the track capacity increased by changing some of the basic infrastructure and operation parameters, for example, the minimal curve radius of the track, the number of tracks, or the usable track length at stations. Calculation of the necessary parameter changes is based on the fundamental physical laws applied to the train movement, and calculation of the occupation time is dependent on the changes of controlling the traffic between the stations.

Keywords: Curve radius, maximum curve speed, track mass capacity, reconstruction.

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Authors: H. Ettouney, A. AL-Haddad, S. Saqer

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This paper focuses on assessment of air pollution in Umm-Alhyman, Kuwait, which is located south to oil refineries, power station, oil field, and highways. The measurements were made over a period of four days in March and July in 2001, 2004, and 2008. The measured pollutants included methanated and nonmethanated hydrocarbons (MHC, NMHC), CO, CO2, SO2, NOX, O3, and PM10. Also, meteorological parameters were measured, which includes temperature, wind speed and direction, and solar radiation. Over the study period, data analysis showed increase in measured SO2, NOX and CO by factors of 1.2, 5.5 and 2, respectively. This is explained in terms of increase in industrial activities, motor vehicle density, and power generation. Predictions of the measured data were made by the ISC-AERMOD software package and by using the ISCST3 model option. Finally, comparison was made between measured data against international standards.

Keywords: Air pollution, Emission inventory, ISCST3 model, Modeling

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Authors: Bi Kun, Gu Nai-jie, Tu Kun, Liu Xiao-hu, Liu Gang

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Traditional parallel single string matching algorithms are always based on PRAM computation model. Those algorithms concentrate on the cost optimal design and the theoretical speed. Based on the distributed string matching algorithm proposed by CHEN, a practical distributed string matching algorithm architecture is proposed in this paper. And also an improved single string matching algorithm based on a variant Boyer-Moore algorithm is presented. We implement our algorithm on the above architecture and the experiments prove that it is really practical and efficient on distributed memory machine. Its computation complexity is O(n/p + m), where n is the length of the text, and m is the length of the pattern, and p is the number of the processors.

Keywords: Boyer-Moore algorithm, distributed algorithm, parallel string matching, string matching.

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Authors: Ashok Kumar Goel, Suresh Chandra Saxena, Surekha Bhanot

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In this work, a Modified Functional Link Artificial Neural Network (M-FLANN) is proposed which is simpler than a Multilayer Perceptron (MLP) and improves upon the universal approximation capability of Functional Link Artificial Neural Network (FLANN). MLP and its variants: Direct Linear Feedthrough Artificial Neural Network (DLFANN), FLANN and M-FLANN have been implemented to model a simulated Water Bath System and a Continually Stirred Tank Heater (CSTH). Their convergence speed and generalization ability have been compared. The networks have been tested for their interpolation and extrapolation capability using noise-free and noisy data. The results show that M-FLANN which is computationally cheap, performs better and has greater generalization ability than other networks considered in the work.

Keywords: DLFANN, FLANN, M-FLANN, MLP

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Authors: Sérgio S. de Jesus, Edgar Leonardo Martínez, Aulus R.R. Binelli, Aline Santana, Rubens Maciel Filho

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The speed profiles, gas holdup (e_G) and global oxygen transfer coefficient (k_La) from a stirred airlift bioreactor using water as the fluid model, was investigated by computational fluid dynamics modeling. The parameters predicted by the computer model were validated with the experimental dates. The CFD results were very close to those obtained experimentally. During the simulation it was verified a prevalent impeller effect at low speeds, propelling a large volume of fluid against the walls of the vessel, which without recirculation, results in low values of e_G and k_La; however, by increasing air velocity, the impeller effect is smaller with the air flow being greater, in the region of the riser, causing fluid recirculation, which explains the increase in e_G and k_La.

Keywords: CFD, Hydrodynamics, Mass transfer, Stirred airlift bioreactor.

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Authors: Al-Shabatat, M. Ahmad, Abbas, M., Ismail, H. Nizam

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Achievement motivation is believed to promote giftedness attracting people to invest in many programs to adopt gifted students providing them with challenging activities. Intellectual giftedness is founded on the fluid intelligence and extends to more specific abilities through the growth and inputs from the achievement motivation. Acknowledging the roles played by the motivation in the development of giftedness leads to an effective nurturing of gifted individuals. However, no study has investigated the direct and indirect effects of the achievement motivation and fluid intelligence on intellectual giftedness. Thus, this study investigated the contribution of motivation factors to giftedness development by conducting tests of fluid intelligence using Cattell Culture Fair Test (CCFT) and analytical abilities using culture reduced test items covering problem solving, pattern recognition, audio-logic, audio-matrices, and artificial language, and self report questionnaire for the motivational factors. A number of 180 highscoring students were selected using CCFT from a leading university in Malaysia. Structural equation modeling was employed using Amos V.16 to determine the direct and indirect effects of achievement motivation factors (self confidence, success, perseverance, competition, autonomy, responsibility, ambition, and locus of control) on the intellectual giftedness. The findings showed that the hypothesized model fitted the data, supporting the model postulates and showed significant and strong direct and indirect effects of the motivation and fluid intelligence on the intellectual giftedness.

Keywords: Achievement motivation, Intellectual Giftedness, Fluid Intelligence, Analytical Giftedness, CCFT, Structural EquationModeling.

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Authors: Bachir Chemani, Rachid Halfaoui

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The aim of work is to define the distribution density of winding yarn on cylindrical and conical bobbins. It is known that parallel winding gives greater density and more regular distribution, but the unwinding of yarn is much more difficult for following process. The conical spool has an enormous advantage during unwinding and may contain a large amount of yarns, but the density distribution is not regular because of difference in diameters. The variation of specific density over the reel height is explained generally by the sudden change of winding speed due to direction movement variation of yarn. We determined the conditions of uniform winding and developed a calculate model to the change of the specific density of winding wire over entire spool height.

Keywords: Textile, cylindrical bobbins, conical bobbins, parallel winding, cross winding.

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Authors: C. Rattanakawin, S. Vasailor

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Acid leaching of flotation concentrate of oxide copper ore containing mainly of malachite was performed in a standard agitation tank with various parameters. The effects of solid to liquid ratio, sulfuric acid concentration, agitation speed, leaching temperature and time were examined to get proper conditions. The best conditions are 1:8 solid to liquid ratio, 10% concentration by weight, 250 rev/min, 30 ^oC and 5-min leaching time in respect. About 20% Cu grade assayed by atomic absorption technique with 98% copper recovery was obtained from these combined optimum conditions. Dissolution kinetics of the concentrate was approximated as a logarithmic function. As a result, the first-order reaction rate is suggested from this leaching study.

Keywords: Agitation leaching, dissolution kinetics, flotation concentrate, oxide copper ore, sulfuric acid.

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Authors: A. M. Maqableh

Abstract:

Modelling techniques for a fluid coupling taken from published literature have been extended to include the effects of the filling and emptying of the coupling with oil and the variation in losses when the coupling is partially full. In the model, the fluid flow inside the coupling is considered to have two principal velocity components; one circumferentially about the coupling axis (centrifugal head) and the other representing the secondary vortex within the coupling itself (vortex head). The calculation of liquid mass flow rate circulating between the two halves of the coupling is based on: the assumption of a linear velocity variation in the circulating vortex flow; the head differential in the fluid due to the speed difference between the two shafts; and the losses in the circulating vortex flow as a result of the impingement of the flow with the blades in the coupling and friction within the passages between the blades.

Keywords: Fluid Coupling, Mathematical Modelling, partially filled.

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Authors: Hou Youfu, Wang Daoming, Meng Qingrui

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To reveal the temperature field distribution of disc brake in downward belt conveyor, mathematical models of heat transfer for disc brake were established combined with heat transfer theory. Then, the simulation process was stated in detail and the temperature field of disc brake under conditions of dynamic speed and dynamic braking torque was numerically simulated by using ANSYS software. Finally the distribution and variation laws of temperature field in the braking process were analyzed. Results indicate that the maximum surface temperature occurs at a time before the brake end and there exist large temperature gradients in both radial and axial directions, while it is relatively small in the circumferential direction.

Keywords: Downward belt conveyor, Disc brake, Temperature field, Numerical simulation.

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Authors: Majed Omar Al-Dwairi

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This paper evaluate the multilevel modulation for different techniques such as amplitude shift keying (M-ASK), MASK, differential phase shift keying (M-ASK-Bipolar), Quaternary Amplitude Shift Keying (QASK) and Quaternary Polarization-ASK (QPol-ASK) at a total bit rate of 107 Gbps. The aim is to find a costeffective very high speed transport solution. Numerical investigation was performed using Monte Carlo simulations. The obtained results indicate that some modulation formats can be operated at 100Gbps in optical communication systems with low implementation effort and high spectral efficiency.

Keywords: Optical communication, multilevel amplitude shift keying (M-ASK), Differential phase shift keying (DPSK), Quaternary Amplitude Shift Keying (QASK), Quaternary Polarization-ASK (QPol-ASK).

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Authors: Navid Javidtash, Abdolmohamad Davodi, Mojtaba Hakimzadeh, Abdolreza Roozbeh

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Economic dispatch (ED) is considered to be one of the key functions in electric power system operation. This paper presents a new hybrid approach based genetic algorithm (GA) to economic dispatch problems. GA is most commonly used optimizing algorithm predicated on principal of natural evolution. Utilization of chaotic queue with GA generates several neighborhoods of near optimal solutions to keep solution variation. It could avoid the search process from becoming pre-mature. For the objective of chaotic queue generation, utilization of tent equation as opposed to logistic equation results in improvement of iterative speed. The results of the proposed approach were compared in terms of fuel cost, with existing differential evolution and other methods in literature.

Keywords: Economic Dispatch(ED), Optimization, Fuel Cost, Genetic Algorithm (GA).

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Authors: Gu Shan-Mao, He Feng-You, Ye Sheng-Wen, Ma Zhi-Xun

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The application of a high frequency signal injection method as speed and position observer in PMSM drives has been a research focus. At present, the precision of this method is nearly good as that of ten-bit encoder. But there are some questions for estimating position polarity. Based on high frequency signal injection, this paper presents a method to compensate position polarity for permanent magnet synchronous motor (PMSM). Experiments were performed to test the effectiveness of the proposed algorithm and results present the good performance.

Keywords: permanent magnet synchronous motor, sensorless, high-frequency signal injection, magnetic pole position.

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Authors: Olumide Simeon Ogunnusi, Shukor Abd Razak, Michael Kolade Adu

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Inter-agent communication manager facilitates communication among mobile agents via message passing mechanism. Until now, all Foundation for Intelligent Physical Agents (FIPA) compliant agent systems are capable of exchanging messages following the standard format of sending and receiving messages. Previous works tend to secure messages to be exchanged among a community of collaborative agents commissioned to perform specific tasks using cryptosystems. However, the approach is characterized by computational complexity due to the encryption and decryption processes required at the two ends. The proposed approach to secure agent communication allows only agents that are created by the host agent server to communicate via the agent communication channel provided by the host agent platform. These agents are assumed to be harmless. Therefore, to secure communication of legitimate agents from intrusion by external agents, a 2-phase policy enforcement system was developed. The first phase constrains the external agent to run only on the network server while the second phase confines the activities of the external agent to its execution environment. To implement the proposed policy, a controller agent was charged with the task of screening any external agent entering the local area network and preventing it from migrating to the agent execution host where the legitimate agents are running. On arrival of the external agent at the host network server, an introspector agent was charged to monitor and restrain its activities. This approach secures legitimate agent communication from Man-in-the Middle and Replay attacks.

Keywords: Agent communication, introspective agent, isolation of agent, policy enforcement system.

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Authors: F.Agalianos, S.Patelis , P. Kyratsis, E. Maravelakis, E.Vasarmidis, A.Antoniadis

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Laser engraving is a manufacturing method for those applications where previously Electrical Discharge Machining (EDM) was the only choice. Laser engraving technology removes material layer-by-layer and the thickness of layers is usually in the range of few microns. The aim of the present work is to investigate the influence of the process parameters on the surface quality when machined by laser engraving. The examined parameters were: the pulse frequency, the beam speed and the layer thickness. The surface quality was determined by the surface roughness for every set of parameters. Experimental results on Al7075 material showed that the surface roughness strictly depends on the process parameters used.

Keywords: Laser engraving, Al7075, Yb: YAG laser, laser process parameters, material roughness.

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Authors: V. Prasannavenkadesan, A. Elango, S. Chockalingam

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During machining process, chatter is an unavoidable phenomenon. Boring bars possess the cantilever shape and due to this, it is subjected to chatter. The adverse effect of chatter includes the increase in temperature which will leads to excess tool wear. To overcome these problems, in this investigation, Cartridge brass (Cu – 70% and Zn – 30%) is passively fixed on the boring bar and also clearance is provided in order to reduce the displacement, tool wear and cutting temperature. A conventional all geared lathe is attached with vibrometer and pyrometer is used to measure the displacement and temperature. The influence of input parameters such as cutting speed, depth of cut and clearance on temperature, tool wear and displacement are investigated for various cutting conditions. From the result, the optimum conditions to obtain better damping in boring process for chatter reduction is identified.

Keywords: Boring, chatter, mass damping, passive damping.

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Authors: Gaurav Shinde, Sai Charan Gongiguntla, Prajwal Shirur, Ahmed Hambaba

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Health issues are significantly increasing, putting a substantial strain on healthcare services. This has accelerated the integration of machine learning in healthcare, particularly following the COVID-19 pandemic. The utilization of machine learning in healthcare has grown significantly. We introduce DeClEx, a pipeline which ensures that data mirrors real-world settings by incorporating gaussian noise and blur and employing autoencoders to learn intermediate feature representations. Subsequently, our convolutional neural network, paired with spatial attention, provides comparable accuracy to state-of-the-art pre-trained models while achieving a threefold improvement in training speed. Furthermore, we provide interpretable results using explainable AI techniques. We integrate denoising and deblurring, classification and explainability in a single pipeline called DeClEx.

Keywords: Machine learning, healthcare, classification, explainability.

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Authors: Hussain H. Al-Kayiem, Goh Jin Ming

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The common practice of operating S-rotor is in an open environment; however there are times when the rotor is installed in a bounded environment and there might be changes in the performance of the rotor. This paper presents the changes in the performance of S-rotor when operated in bounded flows. The investigation was conducted experimentally to compare the performance of the rotors in bounded environment against open environment. Three different rotors models were designed, fabricated and subjected to experimental measurements. All of the three models were having 600 mm height and 300 mm Diameter. They were tested in three different flow environments; namely: partially bounded environment, fully bounded environment and open environment. Rotors were found to have better starting up capabilities when operated in bounded environment. Apart from that, all rotors manage to achieve higher Power and Torque Coefficients at a higher Tip Speed Ratio as compared to the open environment.

Keywords: Bounded Flows, Savonius Rotor, Wind Turbine, Wind energy, VAWT

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Authors: M. H. Pour, V. M. Nansa, M. Saberi, A. M. Ghanadi, A. Aghayari, M. Mirzajanzadeh

Abstract:

Stirred tanks have applications in many chemical processes where mixing is important for the overall performance of the system. In present work 5%v of the tank is filled by solid particles with diameter of 700 m that Rushton Turbine and Propeller impeller is used for stirring. An Eulerian-Eulerian Multi Fluid Model coupled and for modeling rotating of impeller, moving reference frame (MRF) technique was used and standard-k-
model was selected for turbulency. Flow field, radial velocity and axial distribution of solid for both of impellers was investigation and comparison. Comparisons of simulation results between Rushton Turbine and propeller impeller shows that final quality of solid-liquid slurry in different rotating speed for propeller impeller is better than the Rushton Turbine.

Keywords: CFD, Particle Velocity, Propeller Impeller, Rushton Turbine.

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Authors: Sheena Mathew, K. Poulose Jacob

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This paper describes the results of an extensive study and comparison of popular hash functions SHA-1, SHA-256, RIPEMD-160 and RIPEMD-320 with JERIM-320, a 320-bit hash function. The compression functions of hash functions like SHA-1 and SHA-256 are designed using serial successive iteration whereas those like RIPEMD-160 and RIPEMD-320 are designed using two parallel lines of message processing. JERIM-320 uses four parallel lines of message processing resulting in higher level of security than other hash functions at comparable speed and memory requirement. The performance evaluation of these methods has been done by using practical implementation and also by using step computation methods. JERIM-320 proves to be secure and ensures the integrity of messages at a higher degree. The focus of this work is to establish JERIM-320 as an alternative of the present day hash functions for the fast growing internet applications.

Keywords: Cryptography, Hash function, JERIM-320, Messageintegrity

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Authors: Gary D. Cantrell, E. Alex Baylot

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The radius-of-curvature (ROC) defines the degree of curvature along the centerline of a roadway whereby a travelling vehicle must follow. Roadway designs must encompass ROC in mitigating the cost of earthwork associated with construction while also allowing vehicles to travel at maximum allowable design speeds. Thus, a road will tend to follow natural topography where possible, but curvature must also be optimized to permit fast, but safe vehicle speeds. The more severe the curvature of the road, the slower the permissible vehicle speed. For route planning, whether for urban settings, emergency operations, or even parcel delivery, ROC is a necessary attribute of road arcs for computing travel time. It is extremely rare for a geo-spatial database to contain ROC. This paper will present a procedure and mathematical algorithm to calculate and assign ROC to a segment pair and/or polyline.

Keywords: linear features, radius-of-curvature, roads, routing, traffic, turning

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Authors: Masoud Jabbari, Mohammad Kazem Moravvej-Farshi, Rahim Ghayour, Abbas Zarifkar

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In this paper, based on the coupled-mode and carrier rate equations, derivation of a dynamic model and numerically analysis of a MQW chirped DFB-SOA all-optical flip-flop is done precisely. We have analyzed the effects of strains of QW and MQW and cross phase modulation (XPM) on the dynamic response, and rise and fall times of the DFB-SOA all optical flip flop. We have shown that strained MQW active region in under an optimized condition into a DFB-SOA with chirped grating can improve the switching ON speed limitation in such a of the device, significantly while the fall time is increased. The values of the rise times for such an all optical flip-flop, are obtained in an optimized condition, areas tr=255ps.

Keywords: All-Optical Flip-Flop (AO-FF), Distributed feedback semiconductor optical amplifier (DFB-SOA), Optical Bistability, Multi quantum well (MQW)

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Authors: Subrato Saha, Yun-Hyun Cho

Abstract:

This paper presents the design process of a high performance 3-phase 3.7 kW 2-pole line start permanent magnet synchronous motor for pumping system. A method was proposed to study the starting torque characteristics considering line start with high inertia load. A d-q model including cage was built to study the synchronization capability. Time-stepping finite element method analysis was utilized to accurately predict the dynamic and transient performance, efficiency, starting current, speed curve and etc. Considering the load torque of pumps during starting stage, the rotor bar was designed with minimum demagnetization of permanent magnet caused by huge starting current.

Keywords: LSPM, starting analysis, demagnetization, FEA, pumping system.

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Authors: Bohuslava Juhasova, Martin Juhas, Renata Masarova, Zuzana Sutova

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The article deals with the tool in Matlab GUI form that is designed to analyse a mechatronic system sensitivity and tolerance. In the analysed mechatronic system, a torque is transferred from the drive to the load through a coupling containing flexible elements. Different methods of control system design are used. The classic form of the feedback control is proposed using Naslin method, modulus optimum criterion and inverse dynamics method. The cascade form of the control is proposed based on combination of modulus optimum criterion and symmetric optimum criterion. The sensitivity is analysed on the basis of absolute and relative sensitivity of system function to the change of chosen parameter value of the mechatronic system, as well as the control subsystem. The tolerance is analysed in the form of determining the range of allowed relative changes of selected system parameters in the field of system stability. The tool allows to analyse an influence of torsion stiffness, torsion damping, inertia moments of the motor and the load and controller(s) parameters. The sensitivity and tolerance are monitored in terms of the impact of parameter change on the response in the form of system step response and system frequency-response logarithmic characteristics. The Symbolic Math Toolbox for expression of the final shape of analysed system functions was used. The sensitivity and tolerance are graphically represented as 2D graph of sensitivity or tolerance of the system function and 3D/2D static/interactive graph of step/frequency response.

Keywords: Mechatronic systems, Matlab GUI, sensitivity, tolerance.

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Authors: A. Shishkin, V. Mironovs, D. Goljandin, A. Korjakins

Abstract:

The goal of this work is to develop sustainable and durable ceramic cellular structures using widely available natural resources- clay and milled waste glass. Present paper describes method of obtaining clay ceramic foam (CCF) with addition of milled waste glass in 5, 7 and 10 wt% by direct foaming with high speed mixer-disperser (HSMD). For more efficient clay and waste glass milling and mixing, the high velocity disintegrator was used. The CCF with 5, 7, and 10 wt% were obtained at 900, 950, 1000 and 1050 °C firing temperature and they have demonstrated mechanical compressive strength for all 12 samples ranging from 3.8 to 14.3 MPa and porosity 76-65%. Obtained CCF has compressive strength 14.3 MPa and porosity 65.3%.

Keywords: Ceramic foam, waste glass, clay foam, glass foam, open cell, direct foaming.

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Authors: Richard E. Miller

Abstract:

12.7-mm thick plates of 6061-T6511 aluminum alloy and high hardness steel (528 HV) were successfully joined by a friction stir bonding process using a tungsten-rhenium stir tool. Process parameter variation experiments, which included tool design geometry, plunge and traverse rates, tool offset, spindle tilt, and rotation speed, were conducted to develop a parameter set which yielded a defect free joint. Laboratory tensile tests exhibited yield stresses which exceed the strengths of comparable AA6061-to-AA6061 fusion and friction stir weld joints. Scanning electron microscopy and energy dispersive X-ray spectroscopy analysis also show atomic diffusion at the material interface region.

Keywords: Dissimilar materials, friction stir, welding.

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