Optimization of Dissimilar aluminum alloy by Friction stir welding Process Control variables with Multiple Objectives

Abstract

The progress of FSW has offered a different approach for fabricating superior class weld. This paper deals with optimization of process control variables influencing weld features in customized friction stir butt welding having multiple objectives of 6 mm thick dissimilar plates of AA7075 and AA6101 using Taguchi grey relational approach. The L27 orthogonal array has been employed to Obtain the experimental trails and the joints have been fabricated in a laboratory stage friction stir welding equipment by changing tool rotation speed, worktable translational speed, tool plunge force and tool pin shape. After welding, tensile and impact strength of the weld have been evaluated and found that optimum ultimate tensile strength of 129 Mpa., maximum yield strength of 119.21Mpa, maximum % of elongation 24.64% and impact strength 23Mpa simultaneously in FSW process variables of Tool rotation speed is 1200 rpm, transvers speed of 30 mm/min and axial force is at 5 kN. Based on the experimental results optimum levels of process control variables were obtained using grey relation rating and compared with confirmation test.