Optimization of FSW Process Parameters During Joining of Al to Cu Using Taguchi-Based GA

Abstract

Friction stir welding (FSW) is a new and effective solid-state joining process and getting evolved to join the dissimilar materials such as aluminum (Al) and copper (Cu). FSW tool design, geometry, and FSW process parameters possess a considerable impact on the material movement and stirring during joining and govern the microstructure and mechanical properties of the joints. In the present study, the effect of the combination of different process parameters, i.e., shoulder diameter (A), welding speed (B), and rotational speed (C) on the ultimate tensile strength (UTS) during joining of Al-6101, and pure copper has been studied. The joining is performed using the cylindrical tool pin, and the Taguchi’s L9 standard orthogonal array for three process parameters each at three levels are chosen to perform the experimentation. The optimal combination of the FSW parameters yielding maximum UTS is determined using the ANOM (Analysis of Mean), and the significance of each parameter on the UTS is ascertained through ANOVA (Analysis of Variance). It is observed that the UTS of the FSWed joints varied significantly within the selected process parameter range. Further, the observed results were verified by applying genetic algorithm (GA) using the MATLAB software.