Process parameter optimization in friction stir welding process using Taguchi method

Abstract

Friction Stir Welding (FSW) process is an effective welding technique that is used to create high quality solid state joints in industries such as aerospace, automotive and shipbuilding. The significant advantages are no melting and recast issue. In FSW process, profile of tool pin plays a significant part which influence the performance of welded joints. In this investigation, experiments conducted to study the impact of tool pin profile and optimize the process variables in FSW process. Circular, square and triangular types are used as profiles of tool pin in this work. Taguchi orthogonal matrix is used for performing the experiments. Input parameters included are profile of tool pin geometry, rotational speed of tool and welding speed. Response includes tensile strength of the joint and weld’s micro hardness. Taguchi procedure is applied to analyzed the experimental results. Taguchi steps are unique optimization procedure for estimation of optimum selection of process parameters. The experimental result showed that enhanced tensile strength and microhardness with square tool pin profile. It is observed that weld quality is influenced by optimum selection of tool pin’s geometry in FSW process.