Butt Joint Configuration Research Articles

Induction assisted autogenous plasma arc welding of HSLA steel

In this work, a high frequency induction heating (HFIH) assisted plasma arc welding (IPAW) technique is proposed to weld 6 mm thick S690QL high strength low alloy steel plates in square butt joint configuration and without using any filler material. A 3D finite element based coupled electromagnetic-thermal analysis is carried out to ascertain the weld's thermal characteristics. Microstructure evolution and mechanical performance are investigated using scanning electron microscopy, electron back scattered diffraction, transmission electron microscopy, tensile test, Charpy impact test and micro hardness test. The results demonstrate that 15 s initial static heating using a co-directional current coil with magnetic flux concentrator predominantly improves the weld penetration by 48 % and joint efficiency reaches 90 % to the base plate strength. Microstructural study shows that the addition of HFIH promotes low angle grain boundaries (LAGB) with bainite ferrite and granular bainite micro-constituents in the fusion zone, which causes localised yielding and failure in this zone during tensile test. Further investigation reveals that the HFIH encourages the formation of BI-type bainite ferrite laths of 1.3–2.2 μm width, combined with slender martensite-austenite (M-A) island at the bainite ferrite lath boundaries. The results also reveal that the induction heating promotes the formation of M23C6 precipitates and B2 structured Cu-enrich nano precipitates in the fusion zone (FZ). The microhardness distribution indicates that the FZ and coarse grain heat affected zone are significantly reduced due to the assistance of the HFIH. The impact test result shows a lower energy absorption by the IPAW weldments due to dominance of the LAGB with unfavourable strain distribution.

Gap bridging in laser welding of EN AW 5083 with different joint configurations via beam oscillation and filler wire

The extended use of laser welding in the industry requires a less sensitive process in terms of geometrical tolerances of the joint edges. As the industrial availability of laser systems increases, the demand to use laser welding technology possibly with parts coming from less precise production steps is increasing. Gap formation is often caused by the edge quality of the parts coming from previous manufacturing steps such as sheet forming. Al alloy sheets deformed to box-shaped 3D forms often require welded joints on the edges in lap, but, and corner joint configurations. These joints are hard to carry out by laser welding due to the large gap formation caused by the tolerances of the deformation processes involved. Laser welding of Al alloys is already challenging in the absence of gap formation, while these joint configurations have been not feasible with a stationary beam due to incomplete fusion and defect formation. Laser welding with beam oscillation and wire feeding can improve the weldability of these joints. The oscillating motion of the high-intensity beam can achieve a deep weld together with a wider seam. Combined with wire feeding, the process can close gaps in the butt, lap, and corner joint configurations. On the other hand, the added oscillation and wire-related parameters require extending the experimental space, which requires a methodological study to identify feasible conditions. Accordingly, this work proposes a methodological approach to identify and set laser welding process parameters with beam oscillation and wire feeding for an EN AW 5083. Process parameters were initially studied using a simple analytical model that depicts the beam trajectory. Bead-on-plate tests were conducted to assess beam size, power, and weld speed ranges. Lap, butt, and corner joint conditions with a 0.5-mm gap were welded with high quality by manipulating the laser power, oscillation amplitude, and wire feed rate. The results show that welding speeds could be maintained as high as 55 mm/s with complete filling of gaps of up to 0.5 mm, eliminating the surface undercuts and achieving weld widths in the order of 2.5 mm. Moreover the results show the possibility control the depth of the welds from 3 mm to full-penetration conditions.

Friction stir welding of 2507 super-duplex stainless steel: feasibility of butt joint groove filling at different process parameters

ABSTRACT The present work explores the feasibility of groove-filling welding of 6 mm-thick 2507 super-duplex stainless steel (SDSS) in a similar butt-joint configuration using friction stir welding (FSW). A 60° V-groove with a 3 mm root face was designed and machined. The FSW trials were performed at varying rotation speeds (400–600 rpm), downward forces (15–25 kN), and a constant travel speed of 25 mm/min using two WC tools with two different cobalt (Co) contents of 8 and 10 wt.%. The groove filling achievements of the welded joints were monitored using three non-destructive tests: visual, penetrant, and radiographic. All the welded joints were subjected to transverse tensile testing in addition to hardness measurements across the joint area. Microstructure and fracture surface characterisation were also investigated to gain insights into the impact of heat input on joint performance through a comparison with the as-received SDSS. Among the trial FSW processes, the results indicate that the FSW parameters of 25 mm/min, 15 kN, and 400 rpm using a WC-8 wt.% Co tool were successfully used to completely fill the groove and produce a defect-free SDSS butt-joint. This joint has the highest average stir zone (SZ) hardness (342 ± 5 HV) and tensile strength (1256 ± 21 MPa) compared to partially jointed specimens.

Effect of reducing heat input on autogenous TIG welding of Ti–6Al–4V alloy

3 mm-thick Ti–6Al–4V alloy plates were welded in butt joint configuration through autogenous TIG welding method using a trailing gas shielding arrangement. After attaining full penetrated weld joint with appropriate heat input, subsequent experiments were conducted by reducing the heat input, which was obtained through combination of higher welding current and scan speed. An in-depth microstructural analysis of the weld joint executed under different heat input conditions shows a strong correlation with the microhardness, tensile strength, and flexural strength of the weld joint. A significant improvement in the mechanical properties of the weld joint was perceived for employing lower heat input. Alteration in the primary-α, primary-β, and martensite-α phases, due to the variation in heat input, amended the mechanical properties of the weld joint under lower heat input condition. With the reduction of heat input from 0.406 to 0.232 kJ/mm, the tensile and flexural strengths of the weld joint increased from 1020 to 1070 MPa, and from 1015 to 1950 MPa, respectively. The tensile strength of the joint reached up to 98% of the base material at minimum heat input (0.232 kJ/mm). The experimental results show the potential of TIG welding for joining Ti–6Al–4V alloy under low heat input condition.

High-Strength Dissimilar Welds Between a NiTi Shape Memory Alloy and Titanium Obtained by Intermixing Niobium Using Pulsed Laser Beam Welding

Joining of NiTi shape memory alloys with commercially pure titanium (Ti) is of great interest for manifold industrial applications. However, dissimilar fusion welding of these materials is associated with the formation of extremely brittle intermetallic compounds, e.g., Ti2Ni and TiNi3, which drastically limit the mechanical properties of NiTi/Ti joints. The present investigation seeks to improve both chemical compatibility and mechanical performance through intermixing of a niobium foil as filler material into a NiTi/Nb/Ti butt-joint configuration by means of pulsed laser beam welding. Different pulse durations are applied to tailor intermixing and evaluate the deviating chemical compositions of the weld metal. It is demonstrated that intermixing of niobium significantly increases the weldability of the material combination NiTi/Ti compared to autogenous welding. However, the proportion of intermixed filler material exerts a substantial impact on the microstructural evolution and mechanical properties. Ultimate tensile strengths of up to 679 MPa with fracture occurring in the titanium base metal at an elongation at break of 18.7 pct is obtained by a reduction of the pulse duration, which represents a major improvement over previous studies focusing on fusion welding of NiTi to titanium and its alloys.

Influence of dissimilar plate thickness on temperature during friction stir welding between AA5083 and AA6061 aluminium alloy grades

This paper investigates the influence of dissimilar plate thickness on the temperature profile of AA5083 and AA6061 aluminium alloy. Plates of dissimilar aluminium alloy grades are welded in a butt joint configuration by using a milling machine and a custom FSW tool made of H13 tool. Datalogger and type K thermocouples embedded in the workpieces at different distances from the weld line are used to collect the temperature data during the experiment. One thermocouple is placed at each side of the advancing side and retreating side at equally distance from the center line except for Joint 1, 2 and 3. The results show the range of temperature measurement during the experiment is between 300°C and 600°C. FSW process between similar plate thickness produces the highest value of peak temperature and better surface appearance than dissimilar plate thickness. The thermocouples located near the weld line contributed the higher temperature since the heat source comes from the rotating tool. Besides, higher temperatures were recorded at 5 mm thickness of AA6061 aluminium alloy plate located on the advancing side than the retreating side.

The grey-based Taguchi method was used to enhance the TIG-MIG hybrid welding process parameters for mild steel

Metal Industry and Machine Technology Development Enterprise is Ethiopia's leading manufacturing industry, producing a diverse range of industrial machinery and products. The main welding process used to join the products is MIG welding, which has several flaws, including low weld-metal toughness, spatter formation, undercut formation, and finally poor tensile strength and toughness. The company also uses TIG welding, which uses an inert gas to produce less smoke and fumes. While this technology produces precise welds, it is a time-consuming operation with a lower production rate. As a result, a special type of welding process is required that incorporates the properties of both types of welding processes. As a result, the hybrid TIG-MIG welding configuration was proposed. The optimization of process parameters of EN24 mild steel material for TIGMIG hybrid welding is presented in this paper. The test was carried out on a 6 mm EN24 mild steel plate. The butt joint configuration was used. MIG welding current, TIG welding current, MIG welding voltage, TIG welding voltage, and welding gun travel speed were used as process parameters. A single-level L27 orthogonal array is used to optimize process parameters. Tensile and hardness tests are used to evaluate the mechanical properties of the weld joint. The optimum level setting of the test, according to the mean effect plot of GRG, is MIG welding current of 200 A, MIG welding voltage of 15 V, TIG welding current of 200 A, TIG welding voltage of 18 V, and welding gun travel speed of 5 mm/s. The significant process parameters were investigated using ANOVA. MIG welding current and MIG welding voltage were significant factors in the ANOVA, with percentage contributions of 44.19% and 49.20%, respectively. Five confirmation tests were performed, and the results show that the mean grey relational grade of the conformation test was 0.7594, which falls within the 90% confidence interval, indicating that the experiment is reliable. Finally, MIG welding, TIG welding, and TIG-MIG hybrid welding processes were compared, with the results indicating that TIG-MIG hybrid welding has the highest hardness and tensile strength of all. Based on the findings, it is possible to conclude that the company should use the hybrid welding method to improve the weld joint's hardness and tensile strength.

Studies on welding of thin stainless steel sheets with pulsed nanosecond fiber laser in butt joint configuration

In this work, we report full penetration welding of 1.6 mm thick AISI 304L stainless steel sheets in a butt joint configuration using a pulsed nanosecond fiber laser of an average power of 200 W. The welding was carried out by a focused laser beam oscillating in a circular path. The effects of beam oscillation parameters, e.g., amplitude, frequency, and weld speed, on weld morphology and microstructure were studied. Electron back scattered diffraction was used to characterize the weld microstructure and to map the distribution of austenite and ferrite phases in the weld. The solidification mode of the weld was found to change from the equilibrium FA (Ferrite-Austenite) to AF (Austenite-Ferrite) to A (Austenite) on an increase in the cooling rate with a concomitant drop in the fraction of δ-ferrite. The welds were found to be without any cracks with the sporadic presence of porosities. The welds were found to be mechanically strong.

Friction stir welding of thick 7175 aluminium alloy plates for deepwater riser applications

To substantially reduce the cost of extracting petroleum from ultra-deepwater sources, manufacturing risers from 7175 aluminium (Al) alloys rather than steels is being considered. Friction stir welding (FSW), a solid-phase joining technique, is widely applied to 7XXX Al alloys because its mechanical properties are retained within the nugget zone. And, the primary technical objective of the current study is the development of high-strength, corrosion-resistant weldments that connect 7175 Al riser flanges and pipes. However, as the welding thickness increases, the welding speed can be greatly impeded, which lowers the manufacturing efficiency and weakens the mechanical properties in the heat affected zone (next to the nugget). Therefore, obtaining high-performance thick plate 7175 Al alloy joints via FSW is challenging. To overcome this dilemma, the current work optimises the tool design and welding parameters for achieving high-performance joints between 25.4 mm thick 7175 Al alloy plates in butt joint configuration.

Investigating the effects of double-pass TIG welding on the mechanical and microstructural properties of AISI 1008 steel

ABSTRACT Most premature failures of double-pass weldments are associated with limited knowledge of the mechanical and microstructural evolution following the welding process. Thus, this study aims to investigate the effect of double-pass tungsten inert gas welding on the mechanical and microstructural properties of type AISI 1008 mild steel joints. Double-pass TIG welding in butt joint configuration was adopted to weld the plates maintaining a 2.5 mm root gap in between plates. The double-pass tungsten inert gas welded AISI 1008 joints showed improved ultimate tensile strengths in contrast to the unwelded counterpart, with the least joint efficiency of 82.67 % (weld W3). An increase in the heat input led to a corresponding increase in the weld metal hardness, whereas the hardness of the heat-affected zones increased first and then decreased. The internal geometry of the welds reveals an increase in the bead width, height of reinforcement, width of the heat-affected zone, and weld metal area as the heat input increases. Lastly, the microstructural evolutions of the weld metal zones were primarily dominated by widmanstatten ferrite, acicular ferrite, and pearlite structures, accounting for the enhanced tensile strength and hardness of the joints. Meanwhile, the heat-affected zones were characterised by coarse columnar dendrite structures resulting in lower hardness values. This study gives an insight into the mechanical and microstructural properties of the industry’s most frequently used steel grade, which has not been given much attention in past studies. The research finding enriches the welding theory of A1SI 1008 steel for industrial and academic benefits.

Enhancement on the low-pressure shot peened process of monotonic plastic deformation behaviors of Ni–4Cu–3Mo alloy/super austenite stainless steel dissimilar joints using laser beam welding

This research paper mainly discusses the low-pressure shot-peened (LPSP) process of 2 mm thick sheet plates of monotonic mechanical behaviors of Ni–4Cu–3Mo alloy/super austenite stainless steel (SASS) dissimilar materials joint by laser beam welding. Three types of butt joint (Sample-1, Sample-2, and Sample-3) configuration methods of the laser beam welding process were implemented at the Ni–4Cu–3Mo alloy/SASS dissimilar weldments and LPSP weldments. The microstructure image of the fusion zone revealed that the high heat inputs were distributed at the grain boundary and the prior coarse grain structures were converted into NiCr and C–Cr with significant improvement in the α'-martensite structure. To achieve continuous improvement in yield strength of LPSP weldments compared to the dissimilar weldments, the plastic deformations rate was decreased in the shot-peened weldments. The base metals of tensile samples length were prepared as ±5 mm; however, samples clearly indicated that the dissimilar weldments and LPSP weldments showed the failure in the fusion zone. The average elongation of dissimilar LPSP weldments was increased by 13%; however, the heat inputs collapsed the grain boundaries growth and the structure was converted into twin boundaries and α-martensite structures. The hardness measurement at the fusion zone of dissimilar and LPSP weldments was performed and the average hardness value of 290 HV at the fusion zone and 211 HV at the heat-affected zone was observed for LPSP weldments. The fracture morphology revealed that neither major cracks nor minor voids at the fusion zone of the tensile sample were formed.

Gap and Force Adjustment during Laser Beam Welding by Means of a Closed-Loop Control Utilizing Fixture-Integrated Sensors and Actuators

The development of adaptive and intelligent clamping devices allows for the reduction of rejects and defects based on weld discontinuities in laser-beam welding. The utilization of fixture-integrated sensors and actuators is a new approach, realizing adaptive clamping devices that enable in-process data acquisition and a time-dependent adjustment of process conditions and workpiece position by means of a closed-loop control. The present work focused on sensor and actuator integration for an adaptive clamping device utilized for laser-beam welding in a butt-joint configuration, in which the position and acting forces of the sheets to be welded can be adjusted during the process (studied welding speeds: 1 m/min, 5 m/min). Therefore, a novel clamping system was designed allowing for the integration of inductive probes and force cells for obtaining time-dependent data of the joint gap and resulting forces during welding due to the displacement of the sheets. A novel automation engineering concept allowed the communication between different sensors, actuators and the laser-beam welding setup based on an EtherCAT bus. The subsequent development of a position control and a force control and their combination was operated with a real time PC as master in the bus system and proved the feasibility of the approach based on proportional controllers. Finally, the scalability regarding higher welding speeds was demonstrated.

Analysis of fracture toughness and fatigue crack growth rates of electron beam-welded dissimilar nickel-based superalloys: Mode-I cracks oriented normal to the weld

This paper discusses the experimentally obtained results of fracture toughness and fatigue crack growth rates of dissimilar metal-welded joints of Inconel 718 to Nimonic 80A. The dissimilar metal-welded joints were prepared in butt joint configuration using electron beam welding. Mode-I cracks were oriented normal to the weld. The base metals have different yield strength values (plastic mismatch) and ultimate tensile strength values but have the same elastic modulus and thermal expansion coefficients. The experiments were conducted using single-edge notched bend specimen design. The fracture toughness ( J) and fatigue crack growth rates of dissimilar metal-welded joints were affected by the direction of crack growth, such as cracks moving from stronger metal to weaker metal or vice versa. In comparison to Nimonic 80A (base metal), the J value of dissimilar metal-welded joint with crack direction from Nimonic 80A (stronger) to Inconel 718 (weaker) was lower. Moreover, the J value of dissimilar metal-welded joint was higher than that of Nimonic 80A (base metal) when crack traveled from Inconel 718 (weaker) to Nimonic 80A (stronger). In the fatigue crack growth rate test, the crack grew faster as it approached the weld interface from Nimonic 80A toward Inconel 718 due to crack acceleration. Conversely, the crack grew slowly in the opposite direction due to crack shielding. The onset of these effects began sooner for higher loads than lower loads.

Effect of Weld Length on Strength, Fatigue Behaviour and Microstructure of Intersecting Stitch-Friction Stir Welded AA 6016-T4 Sheets.

Friction stir welding is a promising joining process for boosting lightweight construction in the industrial and automotive sector by enabling the weldability of high-strength aluminum alloys. However, the high process forces usually result in large and heavy equipment for this joining method, which conflicts with flexible application. In order to circumvent this issue, a friction stir welding gun has been developed which is capable of producing short stitch welds-either stand-alone as an alternative to spot welds or merging into each other appearing like a conventional friction stir weld. In this study, the influence of the stitch seam length on the strength properties of intersecting friction stir welds is investigated, and the weld is characterized. For this purpose, EN AW-6016 T4 sheets were welded in butt joint configuration with varying stitch lengths between 2 and 15 mm. Both the static and dynamic strength properties were investigated, and hardness and temperature measurements were carried out. The results show a scalability of the tensile strength as well as the fatigue strength over the stitch seam length, while the substitute proof strength is not affected. Hereby, the tensile strength reached up 80% of the base materials tensile strength with the chosen parameter setup. Likewise, the stitch weld length influences the hardness characteristics of the welds in the transition area.

Influence of friction stir welding parameters on the tribological behavior of dissimilar aluminum alloy joint

PurposeAluminum alloys are applicable in marine and aero fields. Alloys AA5083 and AA6061 are aluminum alloys with different chemical and physical properties. Combination of two dissimilar materials could result in enhanced strength. Generally, dissimilar aluminum alloy joint is made by friction stir welding (FSW) to achieve improved physical properties compared with the parent alloys. The purpose of this research is to develop a new FSW dissimilar material with enhanced properties using AA5083 and AA6061 alloys.Design/methodology/approachIn this research, FSW joint was made for butt joint configuration using AA5083 and AA6061 aluminum alloys. Cylindrical pin with threaded profile was used to perform the joint. The tool tilting angle was maintained as constant, and the tool rotational speed and the welding speed were varied. Wear performance and mechanical strength of the joint were analyzed.FindingsThe results revealed that the increase of tool rotational speed led to poor wear performance, whereas increase of welding speed showed a better wear performance. Further, the prepared joint was analyzed for different wear parameters such as sliding velocity and applied load. The results displayed that the increase of sliding velocity exhibited low wear rate and the increase of load showed high wear rate.Originality/valueThis work is original and deals with the wear performance of AA5083–AA6061 joint at different tool rotational and welding speeds.

Effect of tool rotation speed on microstructure and mechanical properties of underwater friction stir welding 6061 aluminium alloy

This work presents the experimental investigation of the effect of tool rotation speed (TRS) on the mechanical properties of the 6061-T6 aluminium alloy weld joint in the underwater friction stir welding (UFSW) process. The experiments are conducted with four different TRS, 710, 900, 1120, and 1400 rpm, and a constant welding speed (WS) of 20 mm/min, respectively. The welding is performed under the water in the butt joint configuration on the vertical milling machine (Model HMT FN2H). The experimental result shows that the average grain size decreases and tensile strength and hardness increases on increasing the TRS up to mid-range of the TRS and further increasing the TRS the trend of grain size and tensile strength and hardness are increases and decreases, respectively. The maximum tensile strength value is 190 MPa, and the minimum grain size is 5 µm at 1120 rpm. Additionally, the optimum condition of tensile strength and weld zone shape is compared with the conventional friction stir welding process, and it is found that tensile strength is increased by 20% and smaller weld zone shape are observed in underwater friction stir welding process. The brittle fracture dominance is observed at lower TRS and ductile dominance fracture in 900, 1120, and 1400 rpm of the weld joint.

Effect of tool rotation speed on mechanical properties of underwater friction stir welding of 6061-T6 and 5083-H12 aluminium alloys

This work presents an experimental investigation of the effect of tool rotation on the mechanical properties of 6061-T6 and 5083-H12 aluminium alloys in the UFSW weld joint. The experiments are conducted in a vertical milling machine (model no. HMT FN2H) at four different tool rotation speeds (TRS), such as 710, 900, 1120, and 1400 rpm, at constant welding speed (WS) of 63 mm/min. The welding was performed under the water in the butt joint configuration in which the 6061-T6 workpiece material is placed on the retreating side (RS) and 5083-H12 on the advancing side (AS). The results show that the performance of the weld joint quality depends on the TRS. The shape and size of the weld nugget zone (WNZ) and thermo-mechanically affected zone (TMAZ) increase with increasing the TRS. The tensile strength of the weld joint and average grain size of the stir zone (SZ) increases and decreases respectively on increasing the TRS 710 to 1120 rpm. Further increasing the TRS, the tensile strength of the weld joint and average grain size of SZ decreases and increases respectively. Additionally, the fracture surface shows the brittle dominance fracture mode at 1400 rpm, and 710 to 1120 rpm weld joints show the ductile fracture mode.

Performance Evaluation of ML-Based Algorithm and Taguchi Algorithm of the Hardness Value of the Friction Stir Welded AA6262 Joints at a Nugget Joint

Nowadays, industry 4.0 plays a tremendous role in the manufacturing industries for increasing the amount of data and accuracy in modern manufacturing systems. Thanks to artificial intelligence, particularly machine learning, big data analytics have dramatically amended, and manufacturers easily exploit organized and unorganized data. This study utilized hybrid optimization algorithms to find friction stir welding and optimal hardness value at the nugget zone. A similar AA 6262 material was used and welded in a butt joint configuration. Tool rotational speed (RPM), tool traverse speed (mm/min), and the plane depth (mm) are used as controllable parameters and optimized using Taguchi L9, Random Forest, and XG Boost machine learning tools. Analysis of variance was also conducted at a 95% confidence interval for identifying the significant parameters. The result indicated that the coefficient of determination from Taguchi L9 orthogonal array is 0.91 obtained while Random Forest and XG Boost algorithm imparted 0.62 and 0.65 respectively. Keywords: Friction Stir Welding; Taguchi; Machine Learning; Hardness; Nugget Zone and Random Forest.

Optimization of TIG Welding Parameters for Ti-6Al-4V Titanium Alloy using the Taguchi Design of Experiment

This paper presents the effect of tungsten inert gas welding parameters (i.e. welding current, welding speed and filler wire speed) on weld bead geometry, notch tensile strength (NTS) and weld bead hardness of 2.0 mm thick annealed Ti6Al4V titanium alloy sheet welded in a square butt joint configuration using Taguchi L9 (33) three level - three factor matrix. Taguchi’s signal to noise ratios was calculated to obtain optimum welding parameters for Vickers hardness at weld area, Notch tensile strength (NTS), Front bead width (FBW) and Front reinforcement height (FRH). Analysis of Variance (ANOVA) was conducted to find statistically significant and insignificant factors with respect to each response. It was noted that welding speed has significant effect on weld hardness, notch tensile strength, front bead width and height. Optimum parameters for hardness were found to be 120A current, 400 mm / min welding speed and 250mm/min filler wire speed. Confirmation test using the optimal levels of welding parameters was also conducted in order to compare predicted results with values obtained through experimentation.

Design and Optimization of Friction Stir Welding of Al-Cu BUTT Joint Configuration using Taguchi Method

Friction stir welding (FSW) is a solid-state welding technique in which the joint quality was predominantly subjected to heat formation throughout the metal welding process. The weld joint produced from FSW was better than the other fusion welding process. In this research, the base plates AA6101 and C11000 of 5 mm thickness were joined using the hardened oil-hardened nonshrinkable steel(OHNS) tool by the FSW method. The design of experiment (DOE) was used to optimize the input parameters such as tool rotational speed (rpm), feed rate (mm/min), and tool pin offset (mm) on output parameter ultimate tensile strength (UTS). The design of experiment (DOE) was carried out by employing a Taguchi L9 orthogonal array, three factors, and three levels for obtaining a quality joint with good strength. The results of nine trial runs from the Taguchi experimental approach were formulated and analyzed using the statistical tool analysis of variance (ANOVA) using MINITAB 19 software. ANOVA analysis was employed to find the contribution of the input parameters toward the output. The optimized input process parameters will help to create effective weld joints. This study revealed that tool pin offset towards softer metal at medium tool rotational speed would create joints with the highest UTS. Scanning Electron Microscope (SEM) was applied to investigate the structural changes in the FSW of Al-Cu joints.Friction stir welding (FSW) is a solid-state welding technique in which the joint quality was predominantly subjected to heat formation throughout the metal welding process. The weld joint produced from FSW was better than the other fusion welding process. In this research, the base plates AA6101 and C11000 of 5 mm thickness were joined using the hardened oil-hardened nonshrinkable steel(OHNS) tool by the FSW method. The design of experiment (DOE) was used to optimize the input parameters such as tool rotational speed (rpm), feed rate (mm/min), and tool pin offset (mm) on output parameter ultimate tensile strength (UTS). The design of experiment (DOE) was carried out by employing a Taguchi L9 orthogonal array, three factors, and three levels for obtaining a quality joint with good strength. The results of nine trial runs from the Taguchi experimental approach were formulated and analyzed using the statistical tool analysis of variance (ANOVA) using MINITAB 19 software. ANOVA analysis was employed to find the contribution of the input parameters toward the output. The optimized input process parameters will help to create effective weld joints. This study revealed that tool pin offset towards softer metal at medium tool rotational speed would create joints with the highest UTS. Scanning Electron Microscope (SEM) was applied to investigate the structural changes in the FSW of Al-Cu joints.