Optimal FSW process parameters for dissimilar aluminium alloys (AA5083 and AA6061) Using Taguchi Technique

Abstract

Friction stir welding (FSW) can produce higher mechanical properties in the weld zone. In this investigation, the effect of friction stir welding (FSW) parameters such as tool rotational speed, welding speed and tool tilt angle on the mechanical properties of yield strength and% of elongation of friction stir welded dissimilar AA5083 and AA6061 aluminium alloy was studied. The experiments were conducted as per Taguchi parametric design concepts and an L9 orthogonal array was used to study the influence of various combinations of process parameters. Statistical optimization technique, ANOVA was used to find the optimum levels and to determine the significance of each process parameter. The results indicate that tool rotational speed (RPM), and welding speed (WS) are the most significant factors, followed by tool tilt angle (TTA) in deciding the mechanical properties of friction stir welded aluminium alloy. Also, mathematical models were developed to build up the relationship between various process variables and mechanical properties. The resulting optimum process parameters are rotation speed at 1120 rpm, welding speed at 70 mm/min and tool tilt angle at 20, for the best multiple performance characteristics with minimum cost.