Optimization of Sustainable Process Parameters of Friction-Stir Welding of Aluminium Alloy by Taguchi Method

Abstract

In the current paper, AA6101-T6 aluminium alloy was subjected to friction stir welding (FSW) utilizing a vertical milling machine. Alloy plates were welded in butt position to provide a virtually flat interface, using a tool shape that was carefully selected. Because of the excessive generation of heat via the tool and workpieces during friction stir welding, substantial deformation in the nugget zone is seen. The mechanical attributes of the base metal at the joint are significantly impacted by an excessive variation in temperature at the weld. In this experiment, mechanical properties-related changes through the FSW process are kept to a minimum to achieve high tensile strength. The tool’s rotating speed (measured in rpm), the workpieces' traverse speed (measured in mm/min), and the tool tilt angle were chosen as the parameters to regulate the weld quality. As a result of its 44% contribution, the rotating speed parameter is shown to be the most beneficial one for stir welding. The metric determining transverse speed contributes the least, at 19%. For effective stir welding, such as high strength welds, defect-free welds, short welding times, low welding costs, etc., it is preferred that the tool rotational speed parameter be concentrated. By using sustainable Taguchi approach to optimize the chosen process parameter, high tensile strength is achieved at the welded connection.