Optimization of process parameters of metal inert gas welding process on aluminum alloy 6063 pipes using Taguchi-TOPSIS approach

Abstract

To achieve a superior-quality weld, it is imperative to employ the appropriate welding parameters. In this study, the Taguchi-based technique for order of preference by similarity to ideal solution (TOPSIS) method has been used to improve the welding parameters such as current, voltage, and travel speed for metal inert gas (MIG) welding on the AA6063 aluminum alloy. Experiments have been performed to assess the hardness and strength characteristics of the joints. The assignment of the specimen was determined by the TOPSIS algorithm, which considers the specimen's performance score. The analysis of variance (ANOVA) approach was performed to identify the parameter with the highest significance level. A mathematical model has been established using a regression equation to establish a relationship between performance scores' signal-to-noise (S/N) ratio and process parameters. The optimal parameters for the butt joint welded using the MIG technique were determined to be a current of 120 A, a voltage of 20 V, and a travel speed of 3 cm/min. The ANOVA findings reveal that the current factor exhibits the highest level of statistical significance, accounting for 63 % of the observed variation. This was followed by voltage and travel speed, which contributed 24 % and 10.3 %, respectively. To ensure the validity of the findings, a confirmatory experiment was conducted using parameters optimized for analysis. The results of the confirmation indicate a strong alignment with the approach that was implemented.