Abstract
In this paper, the optimization of Friction Stir Welding (FSW) parameters used to produce dissimilar non-ferrous butt joints of Al6061 and AZ31 alloys is investigated carefully. FSW parameters including tool rotation speeds (TRS) ranging between 700–1100 rpm, traverse speed (TS) 40–80 mm/min, and axial load (LA) 7–11 KN are considered for finding suitable FSW parameters. The experiments are carried out at different combinations of FSW parameters and the results are measured using respective equipment. The L18 orthogonal array of Taguchi design of experiments is adapted for Grey relation analysis (GRA) multi-objective optimization aiming for high tensile strength and less wear rate with measured responses. Based on grey relational grade, TRS, TS, and axial load of 1100 rpm, 60 mm/min, 9KN are found to best suitable FSW parameters with reasonable tensile strength of 132.43 MPa, microhardness of 70.4 Hv, and lower wear rate of 5.156 mm3/m, respectively. The confirmatory test has been performed to verify the finding of the optimization study with a maximum error percentage of 2%. Furthermore, the corrosion analysis has also been performed for the produced FSW butt joint at a suitable parametric combination. Corrosion behavior is improved due to equiaxed grain distribution and formed hard Mg2Si precipitates that reduce the differential dissolution effect when embedded in Al matrix. It signifies the improvement in chemical inertness in application to extreme temperature environments.
Published Version
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