Optimization of gas tungsten arc welding parameters on mechanical properties of dissimilar AA2024 and AA6061 Aluminium alloys using Taguchi’s grey relational analysis

Abstract

Due to the high strength to weight ratio and structural strength, aluminum alloys have potential applications in the aerospace, defense, and automobile industries. However, fusion welding of dissimilar aluminum alloys remains challenging for the manufacturers. This paper solely deals with the effects of welding current, gas flow rate, and filler diameter on three mechanical properties of two dissimilar AA2024 and AA6061 gas tungsten arc welded joints. A multi-response optimization was carried out using grey relational analysis. For designing the experiments, Taguchi L9 orthogonal array was employed, and the Tungsten Inert Gas (TIG) butt welding was carried out. Then, the samples were tested for mechanical properties such as hardness, tensile and flexural strength. The optimal process parameters from grey relational grade obtained were welding current 140A, gas flow rate 15 lpm, and electrode diameter 3.2 mm. Electrode diameter has more influence on mechanical properties when compared to the other two variables.