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ORIGINAL RESEARCH article

Front. Control Eng.
Sec. Control and Automation Systems
Volume 5 - 2024 | doi: 10.3389/fcteg.2024.1459399

Workpiece Temperature Control in Friction Stir Welding of Inconel 718 through Integrated Numerical Analysis and Process Control

Provisionally accepted
Ahmed Abotaleb Ahmed Abotaleb 1Mohammed Al-Azba Mohammed Al-Azba 2*Marwan Khraisheh Marwan Khraisheh 3Yves Remond Yves Remond 1Said Ahzi Said Ahzi 1
  • 1 Laboratoire ICube, Université de Strasbourg, Strasbourg, Alsace, France
  • 2 Hamad bin Khalifa University, Doha, Qatar
  • 3 Texas A&M University at Qatar, Doha, Qatar

The final, formatted version of the article will be published soon.

    Friction stir welding (FSW) offers significant advantages over fusion welding, particularly for high-strength alloys like Inconel 718. However, achieving optimal surface quality in Inconel 718 FSW remains challenging due to its sensitivity to temperature fluctuations during welding. This study integrates finite element simulations, statistical analysis, and advanced control methodologies to enhance weld surface quality through adequate thermal management. High-fidelity simulations of the FSW process were conducted using a validated 3D transient COMSOL Multiphysics model, producing a comprehensive dataset correlating process parameters (rotational speed, axial force, and welding speed) with workpiece temperature. This dataset facilitated statistical analysis and parameter optimization through Analysis of variance (ANOVA) method, leading to a deeper understanding of process variables. A nonlinear state-space system model was subsequently developed using experimental data and the system identification toolbox in Matlab, incorporating domain-specific insights. This model was rigorously validated with an independent dataset to ensure predictive accuracy. Utilizing the validated model, tailored control strategies, including proportional-integral-derivative (PID) and model predictive control (MPC) in both single and multivariable configurations, were designed and evaluated. These control strategies excelled in maintaining welding temperatures within optimal ranges, demonstrating robustness in response times and disturbance handling. This precision in thermal management is poised to significantly refine the FSW process, enhancing both surface integrity and microstructural uniformity. The strategic implementation of these controls is anticipated to substantially improve the quality and consistency of welding outcomes.

    Keywords: Friction stir welding, Inconel 718, thermal management, model predictive control, PID

    Received: 04 Jul 2024; Accepted: 17 Oct 2024.

    Copyright: © 2024 Abotaleb, Al-Azba, Khraisheh, Remond and Ahzi. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.

    * Correspondence: Mohammed Al-Azba, Hamad bin Khalifa University, Doha, Qatar

    Disclaimer: All claims expressed in this article are solely those of the authors and do not necessarily represent those of their affiliated organizations, or those of the publisher, the editors and the reviewers. Any product that may be evaluated in this article or claim that may be made by its manufacturer is not guaranteed or endorsed by the publisher.