Optimization of friction stir welding process parameters using MCDM method

Abstract

Friction Stir Welding (FSW) is categorized into a solid-state welding process which is preferred to join aluminum-based materials effectively. Generally, aluminum-based materials are welded using solid state welding than fusion-based welding due to the chance of hot cracking, loss of elements and porosity. Process parameters and its selection in FSW process are important and it leads to efficient of weld quality. Taguchi concept is a standard optimization procedure but it has a limitation of not capable to solve multi objective problems simultaneously. Multi Criteria Decision Making (MCDM) method can be used for solving multiple objectives simultaneous effectively. Al-6061 T6 alloy is used as workpiece and carbon steel, H13 tool steel and high carbon high chromium steel is used as tool materials. The important process parameters considered are rotational speed of tool and welding speed. Response parameters selected are tensile strength and microhardness of welded joints. Process parameters are optimized using MCDM method and the optimum values obtained are rotational speed of 700 rpm and welding speed of 35 mm/min. It is understood that better tensile strength and microhardness of FSW joints at optimized condition due to adequate material flow, fine grain size and pulsating action. MCDM method has simple calculation procedure and easier solving methodology for machining parameters optimization.