Parameter design in friction welding of Al/SiC/Al2O3 composite using grey theory based principal component analysis (GT-PCA)

Abstract

Solid-state welding processes have widened the scope of joining metal matrix composites. The aim of this work was to study the possibility of producing good quality joints with Al/SiC/Al2O3 composites using continuous drive friction welding. Taguchi’s L9 orthogonal array was used to study the effect of welding parameters like frictional pressure, upset pressure, burn off length and rotational speed on the quality characteristics of joints. The quality of joints was evaluated by observing the tensile strength, elongation and micro hardness. An integrated approach of GT-PCA which combines the methodology of grey theory and principal component analysis (PCA) was used to predict the optimal level of friction welding parameters. Frictional pressure was identified as the prime parameter affecting the observed responses. Microstructure of the weld zone was examined using optical microscopy and the fractured surface was also investigated using the field emission scanning electron microscopy images.