Welding Operations Research Articles

SIMULATION OF DYNAMIC EXPLOSIVE LOADING OF THE BODY OF A SPECIALIZED ARMORED VEHICLE

The aim of the work is a simulation of dynamic explosive loading of the body of a specialized armored vehicle based on the development of theoretical foundations of shape change under the action of pulsed influence and calculation of power parameters. The further equation of the stress state at the point of the material under the conditions of pulse loading was obtained, the methods for determining the principal stresses and the invariant of the stress tensor considering the pulse nature of the load were established. The nature of the formed shock wave behavior due to the detonation of an explosive has been established. Analytical dependencies of the interaction of the shock wave with the loaded surface are made. A mathematical apparatus for calculating such parameters of the shock wave as the pressure of the detonation front and its change in time and the velocity of the shock wave at the time of reaching the surface has been developed. The authors developed and proposed an iterative procedure that allows determining the current values of stresses and strains passing through the points of the actual stresses curve, as well as the stresses and strains intensity during pulse loading of metals. A qualitative analysis of the developed models is performed and the values obtained during numerical simulation in the Ansys AUTODYN of the stress-strain state of workpieces during the explosive expansion using an iterative procedure. Using the analytical method proposed in the work, the theoretical calculation of mine resistance of the MPV's bodies was performed in accordance with the requirements of the NATO AEP-55 STANAG 4569 standardization agreement. The solution to this problem can be used in the future to evaluate the plastic properties of materials during welding and blast hardening; with explosion stamping of blanks and combined welding and explosion stamping operations; with impulse methods of stamping - magnetic-pulse, electro-hydraulic, gas detonation, etc., when parts of the workpiece collide with the matrix, and the other part continues to deform; when stamping on hammers; when crushing materials by the impact of a rigid body; explosion crushing of multicomponent environments; determined ballistic resistance of elements of combat equipment. Keywords: simulation, explosive loading, impulse impact, specialized armored vehicle, mine resistance.

Особенности формирования сварного соединения сплава ВТ14 сваркой трением с перемешиванием с использованием жаропрочного инструмента из сплава ЖС6У

Introduction. The technological process of fabrication products from titanium alloys is often complicated by low quality of welded joints during electric arc or gas-flame welding operations due to high residual stresses and deformations. An example of a successful solution to this problem is the development and implementation of such high-tech processes of metal joining as friction stir welding, which does not refer to the methods of fusion joining. Friction stir welding as an advanced technology is used to obtain joints of “soft” metallic materials, such as aluminum. For “hard” metallic materials, friction stir welding has been limited due to the high demands on welding tools. The aim of this work is investigation of the possibility of using a tool made of the nickel-based heat-resistant alloy ZhS6U in friction stir welding of the titanium alloy Ti-5Al-3Mo-1V. Results and discussion. Optical and scanning electron microscopy results revealed that the structure of the weld is typical of this type of welding, gradient, consisting of a heat-affected zone, thermo-mechanical affected zone and a stir zone with a fragmented structure. When varying welding parameters, it is shown that the defectiveness of the weld is affected to a greater extent by the axial load on the tool, which is caused by a significant difference in the thermal effect on the material. Metallographic analysis methods revealed dissolution of welding tool material fragments in the stir zone of the non-detachable joint. Fractographic analysis of the fracture surface shows that the fracture in the weld zone is ductile, although in this case there are brittle bridges. Varying the parameters of friction stir welding made it possible to obtain an indissoluble joint with at least 90 % of the strength of the base metal.

Electron-Beam Welding Cu and Al6082T6 Aluminum Alloys with Circular Beam Oscillations

In this study, we present the results from electron-beam welding operations applied on copper and Al6082T6 aluminum alloys. The influence of beam-scanning geometries on the structure and mechanical properties of the welded joint is studied. The experiments were conducted using a circle oscillation mode with an oscillation radius of 0.1 mm and 0.2 mm. The beam deflection was set to 0.4 mm with respect to the side of the aluminum alloy, and the beam power was set at 2700 W. The phase composition of the obtained welded joints was studied by X-ray diffraction (XRD). Scanning electron microscopy (SEM) was used for the investigation of the microstructure of the joints. The chemical composition was investigated by using energy-dispersive X-ray spectroscopy (EDX). The mechanical properties were studied by micro-hardness investigations. The fusion zone of the weld seam contains three phases—an aluminum matrix, an ordered solid solution of copper and aluminum in the form of CuAl2, and pure copper. Electron beam-scanning geometries have significant influences on the structure of the weld. Increasing the beam oscillation’s radius leads to a decrease in intermetallic phases and improves homogeneity. The measured microhardness values in the fusion zone are much higher than the ones measured in the base metals due to the formation of intermetallic phases. The microhardness of the weld joint formed using an oscillation radius of 0.2 mm was much lower compared to the one formed using an oscillation radius of 0.1 mm.

Using the decision theory in chossing a welding equipment with ultrasounds

For any vehicle, the electric equipment is a basic component, of which functionality has repercussions on consumption, pollution, driving comfort, road safety, etc. Car manufacturers pay special attention to improving the price quality ratio and customer satisfaction. In this sense, they are constantly concerned by refurbishment and use of the latest research results in production processes. This paper presents the aspects the operation of ultrasonic welding in the technological process of car wiring manufacturing and the use of a method from decision theory to replace the current ultrasonic welding equipment, respectively, the welding machine with ultrasounds Minik II, with a more productive modern variant and which leads to a superior welding quality.

A review on materials processing using microwave radiation

Welding is one among the most popular industrial production techniques. The traditional welding procedure has several disadvantages, such as increased energy consumption, longer melting periods and low heat transfer rate. Innovative welding processes are being developed to alleviate the shortcomings of traditional welding methods. Recently, a revolutionary method called microwave joining has emerged. It may be used to treat a diverse variety of materials, including metal matrix composites, polymers, alloys, ceramics, metals, powder metallurgy, material joining, coatings and claddings. This research explored the introduction of microwave welding with hybrid technology and contributions from other researchers, which shed light on numerous research prospects in the field of microwave welding. The welding setup, the technique, and step-by-step welding operation were all thoroughly addressed. Finally, Conclusions were discussed, as well as future recommendations.

Generation of a Robot Program and Determination of an Optimal Workpiece Placement Considering the Manipulability of Industrial Robots

Various operations in the production sites of manufacturing industries are being automated using industrial robots instead of operators. In recent years, an offline teaching method for robot motion has been implemented, where programs are generated in a work environment that is reproduced virtually inside a computer. However, the robot program developed using the offline teaching method can pass through singularities or suddenly change the robot’s posture, making the robot incapable of performing safe operations. To achieve optimal operation, the operator must determine the workpiece placement and create a robot program through trial and error. In this study, we proposed a method that uses manipulability to generate a program that commands the robot to move without passing singularities or changing the robot’s posture. Manipulability is quantitatively evaluated as an indicator of a robot’s ability to move its end effector in arbitrary directions. We proposed another method to determine the optimal workpiece placement for robot operations that can maximize the sum of manipulability during the operation. We implemented the aforementioned methods in an offline teaching system. We applied the developed system to a welding operation and verified its effectiveness by conducting motion simulations. The developed system was able to generate a practical robot program that maintained high manipulability and did not cause sudden changes in the posture or pass singularities. The developed system was able to simultaneously determine the optimal workpiece placement for the task, thereby confirming the usefulness of the proposed method.

A Smart Handheld Welding Torch Device for Manual Spot Laser Welding

In producing custom-made systems, using a robotic welding line that can fine-tune welding parameters is not economical, and laser welding is usually done manually. The most common operator error in manual welding operations is the angular positioning error between the laser beam and the plate surface. This study introduces a smart handheld welding torch device that assists the welding operator with visual warnings. It measures the sheet surface angle to eliminate angular positioning errors, calculates the appropriate torch holding angles accordingly, and helps the laser welding process with the right angle. For this purpose, this study focused on micro-laser spot welding applications of stainless (inox) kitchen and hotel equipment, and the effect of angular positioning errors on the welding quality was investigated experimentally. Experiments show that when the angle between the surface normal and the welding torch is smaller than the critical welding angle, heat-induced traces or micro-deformations occur on the visible surface of the thin stainless material. In addition, there is a significant decrease in the weld quality, since a large enough weld area cannot be created at large values of this angle. The optimum torch angle range was determined using experimental results for the available laser welding parameters. With a standard welding torch and the smart torch, the welding operator was allowed to repeat the same task, and the payloads of the samples prepared in this way were measured. Test results show that using a smart welding torch with an angular positioning assist system significantly improves welding quality. Breaking force values vary in a wide range of welds made with a standard welding torch, and visual problems such as burning, puncture, and swelling are encountered on the visible surfaces of many samples with high strength values. When the developed smart torch was used, the breaking force remained within the desired reference range, and no visual defects were found in any sample.

Investigating the heat distribution on welded parts from a TIG welding operation in a railcar manufacturing environment

Investigating the heat distribution on welded parts from a TIG welding operation in a railcar manufacturing environment

Effect of heat source parameters on weld formation and defects of oscillating laser-TIG hybrid welding in horizontal position

In this paper, a comparison study of the narrow gap horizontal welding characteristics of tungsten inert gas (TIG) welding, non-oscillating laser-TIG hybrid welding, and oscillating laser-TIG hybrid welding is presented. Weld forming tests were performed using various heat source mode parameters. The plasma behavior, the molten pool flow, and the keyhole behavior of these different heat source modes were observed. In addition, filling welding operations were performed, and the defect generation mechanism was analyzed. The results show that oscillating laser-TIG hybrid welding can improve weld formation effectively and suppress defects such as weld porosity and incomplete fusion. The coupling effect of the laser-TIG arc weakens as the oscillation amplitude and the distance between the laser and the tungsten electrode increase. The hybrid plasma generates periodic changes with the laser oscillation, which results in a more uniform energy distribution that improves the sidewall fusion and prevents the formation of large numbers of bubbles. The keyhole stirs the molten pool and drives the molten pool to scour the groove sidewall, which helps to improve the sidewall fusion and suppress pore formation. The oscillating laser-TIG hybrid welding process with an oscillation amplitude of 4 mm and a distance of 3 mm between the laser and the tungsten electrode obtained high-quality welds with good weld morphology.

Numerical and thermal analysis of mechanical properties degradations and distortions in steel weld joint

To quantify the degradation of mechanical properties and material distortion associated with steel weld. Twin mild steel plates each of dimension 20 mm × 100 mm × 6 mm were joined in butt configuration using the arc welding method. Thermal and mechanical analyses of the system were carried out using a numerical method and the associated heat transfer/stress distribution problems were formulated based on FEM. The thermal analysis involves numerical evaluation of the transient temperature distribution in the specimen. The effects of some operational parameters including welding speed and welding power on the temperature profile were studied independently. The results suggest that a good combination of these operational variables guarantees stable welding operation which in turn assists in achieving a quality welded joint. The numerical results were validated using experimental data and further applied to solve the prevailing mechanical problem. The maximum residual stress of 200 N/mm2 was recorded along the weld line while a maximum distortion of 15 mm was recorded numerically at the free end of the steel segment at the prevailing stress condition. Therefore it is recommended that maintaining low but sufficient high welding power helps to minimize excessive temperature rise in the base metal and improves stress distribution along the welding line, which in turn mitigates degradation of tensile strength and other mechanical properties.

Novel method for welding gantry robot scheduling at shipyards

ABSTRACT Welding is the most critical operation in the shipbuilding process and has a significant influence on the production cost and quality of ships. Therefore, the welding operation must be optimised. This paper presents a real-world welding gantry robot scheduling problem at shipyards, in which three gantry robots function in parallel. Welding gantry robots cannot cross each other and should operate over a certain distance to avoid collisions. To minimise the makespan, the welding tasks given by line segments should be evenly distributed among the three gantry robots. The welding tasks assigned to each robot should be optimally sequenced to minimise the completion time, including the waiting time required to prevent collisions with neighbouring robots. In addition, long welding edges are split, and the split small length edges are assigned to the gantry robots. This paper proposes a mixed-integer linear programming model, three-stage solution approach, and variable neighbourhood search algorithm to solve this problem. Experimental tests conducted on 20 real problem instances revealed that the proposed approach can reduce the makespan by 14% on average when compared with the conventional method.

Development and integration of laser sensor tracking system in robotic arm for path correction during welding operation

<span lang="EN-US">An industrial robot is mainly used for manufacturing. Industrial robots are 6 or more axes, which can be automatically controlled by programming. Typical applications of robots include welding, painting, picking, and placing printed circuit boards, packaging and labelling, palletizing, product inspection, and testing with high accuracy, precision, and fast speed. Robotic welding is a complex, nonlinear and time varying process which can be affected by various natural or any random disturbances. Due to the effect of various factors, the actual welding path may differ. So, welding robots should be able to detect the actual welding path, then adjust the difference in welding path and complete the welding process accurately. Laser welding is one of the most important technologies in the manufacturing field. It is the most frequently used technology which has made new demands. So, the manufacturer ensures to meet the quality of laser welding and improve the production efficiency. Due to the increase in demand of quality, accuracy, precise, productivity, flexibility and adaptive control of welding robot, an automatic laser seam tracking system is developed with welding robot to precisely follow the welding path and make the necessary corrections during welding operations.</span>

Welding characteristics and microstructure of an industrially processed Fe-Mn-Al-Ni shape memory alloy joined by tungsten inert gas welding

Iron-based shape memory alloys have recently attracted increased attention due to their low material costs combined with good workability and high transformation strains. They show excellent welding properties, as shown by several studies and compared to non-iron-based shape memory alloys, and are potential candidate materials for large-scale application as damping elements in building structures. Since subsequent heat treatment is only possible to a limited extent for large-scale components, it is necessary to minimize the effects of processing and welding operations on the shape memory properties. Therefore, a suitable microstructure must be established in the heat-affected zone and the fusion zone during the welding process. Thus, industrially processed polycrystalline Fe-Mn-Al-Ni was joined by tungsten inert gas welding with matching filler material. The phases formed upon welding with different parameters were investigated using optical microscopy, scanning electron microscopy and X-ray diffraction. Shielding gas composition as well as mean arc linear energy have a huge impact on the γ-phase precipitation. Intercrystalline cracking can be supressed by increasing the γ content. Further, the α-fraction and grain size in the fusion zone can be controlled by the welding parameters. Ultimately, a hardness value of the fusion zone equal to heat-treated material was achieved which suggests that the fusion zone may be able to transfer the stress required for martensitic transformation.

A computational framework based on FEA, ML and GA for estimation of welding residual stresses

The present work describes a computational framework based on finite element (FE) analysis and machine learning (ML) and genetic algorithm (GA) to accurately estimate and minimize the residual stresses in welding. The FE analysis comprises of sequentially coupled thermal and mechanical analyses that are nonlinear due to temperature-dependent thermal/mechanical properties. In the FE analysis, the effective stress function (ESF) algorithm is used for accurate computation of the temperature-induced elasto-plastic stress field during welding. The ESF algorithm accounts for the large variation of yield curves due to temperature changes in welding. To improve the accuracy of the thermal and mechanical analyses, an optimization process combining supervised machine learning and binary coded genetic algorithm is utilized. This optimization technique is implemented to derive an accurate phase-change model for the thermal FE analysis of SS304, which is otherwise a burdensome and costly task to obtain from calorimetric experiments. The results obtained through the derived phase-change model are validated through welding time-temperature distribution reported for a welding experiment in literature. The same optimization process is further used to obtain a set of weld operating conditions (such as weld voltage, current, welding speed, and the gap between plates) for SS304 that reduce the tensile residual stresses. It is found that the accurate estimation and reduction of welding residual stresses can be realized by using the present computational framework. • A detailed FE analysis is presented for the estimation of residual stresses in welding. • ESF algorithm implemented in the FE analysis is found very useful. • An optimization methodology is proposed based on machine learning and genetic algorithm. • Proposed optimization scheme is used to estimate the phase-change model and weld parameters. • Accuracy in estimation of welding temperature field is improved and tensile residual stress is minimized to a certain extent.

Enhanced resistance to gas tungsten arc weld heat-affected zone cracking in a newly developed Co-based superalloy

The occurrence of heat-affected zone (HAZ) cracking and the effect of pre-weld microstructural modifications on HAZ cracking susceptibility of newly developed cobalt-based superalloy welded by gas tungsten arc welding (GTAW) process is investigated. Microstructural examination shows that a primary cause of HAZ cracking is the sub-solidus liquation of MC-type carbide and γ′ precipitates, which are identified by transmission electron microscopy (TEM) as present in the material before the welding process. Total crack length (TCL) analysis on pre-weld heat-treated samples reveals that pre-weld hardness does not control the HAZ cracking susceptibility during welding. Time-of-flight secondary ion mass spectrometry (ToF-SIMS) coupled with HAZ TCL analysis confirms that grain boundary (GB) elemental segregation of Boron (B) controls the cracking susceptibility during welding. In addition, it is observed that reduction in grain size aids the alloy's resistance to HAZ cracking. Accordingly, a new pre-weld heat treatment that couples reduction in GB segregation of B with small grain size, is found to effectively suppress the HAZ cracking not only after welding, but also after post-weld heat treatment (PWHT). Furthermore, the new pre-weld heat treatment produces tensile properties, after PWHT, that are comparable to those of the alloy without the welding operation, which demonstrates that the pre-weld heat treatment prevents the deleterious effects of welding on tensile properties of the new superalloy.

RESEARCH AND OPTIMIZATION OF REFURBISHMENT OF HPT BLADES OF THE D-18T AIRCRAFT GAS TURBINE ENGINE BY MICRO-PLASMA POWDER WELDING

In current work, peculiarities of the micro-plasma powder welding deposition process applied to the batch refurbishment of D-18T aircraft engine HPT blades made of ZhS32-VI nickel superalloy with limited weldability have been studied. It has been demonstrated that extending operating resource over 6-8 thousand hours leads to an increase in ZhS32-VI “base-deposited metal” weld’s cracking susceptibility during welding and subsequent thermal processing operations. It has been shown that providing stable forming of deposited bead on the shroud edge’s surface requires applying nonstationary impulse modes of straight polarity welding current. Considering the significant amount of technological parameters of the process studied, subjective analysis of such welding modes is extremely complicated. We have introduced the method of specifying requirements for such single-layer micro-plasma powder welding deposition modes with welding current in a range of 7-20 A according to the criteria of effective arc heating power and heat input, which involves using the system for registration and digital processing of welding current-welding bead deposition time dependency. Based on the analysis of statistical data on the quantitative evaluation of cracking susceptibility of the investigated weld, the optimal range of average values has been discovered for these generalized welding deposition mode parameters to be applied in a manual or automated process, which provides no more than several percent of cracked blades detected at the end of refurbishment technological cycle. We have shown that significant technological parameters, which affect the amount of technological defects during mentioned blades’ refurbishment, are the average value of effective welding current and ZhS32 superalloy powder quality, primarily determined by oxygen and nitrogen average weight content in its dispersed particles. It was also shown that the increase in average weight content of gas impurities in the filler powder, primarily oxygen, causes a significant increase in energy consumed on deposited bead formation during the micro-plasma powder deposition process. An initial quality control method for the ZhS32-VI filler powder range has been proposed. The method is based on the average weight content of oxygen and nitrogen, evaluated by reducing fusion in transporting gas flow and on evaluation criteria of effective arc heating power and heat input average values of witness sample blades’ refurbishment process and their conformity to previously defined optimal. An evaluation of future application possibilities for registration systems and deposition mode analysis in batch repair conditions of nickel superalloy aircraft parts has been introduced.

Research on trajectory planning of sub-assembly and unit-assembly robot in shipbuilding industry

In shipbuilding, welds in sub-assemblies and unit-assemblies are long and various type. The robot arm needs the gantry movement to cooperate with the welding operation. However, there are joint redundancy and double-arm coordination problems, which cause difficulties in the welding trajectory planning. This paper proposes a strategy of decoupling the dual-arm system into a single-arm system for separate planning and prioritizing joint motion, and conducts welding trajectory planning research based on Matlab’s Simscape Multibody. Firstly, the 3D model of the welding workstation is established, its structure, the operation mode of the joint link and the degree of freedom are analyzed. The 17-DOF welding workstation is decoupled into a single-arm 9-DOF system, a kinematic model is established, kinematic analysis is carried out. The Matlab robot toolbox is used for simulation verification. Then the discretization of weld types and poses in sub-assemblies and unit-assemblies workpieces is analyzed. Finally, the welding workstation and workpiece model are imported into Simscape Multibody of Matlab to simulate the trajectory planning of different types of welds. The simulation results prove the effectiveness of the strategy and have certain reference significance for on-site welding in shipbuilding.

MECHANICAL AND MICROSTRUCTURAL ANALYSIS IN GJS 400-15 DUCTILE IRON WELDING WITH Fe-Ni AS FILLER METAL, CARRIED OUT BY SMAW AND TIG WELDING WITH DIFFERENT HEAT TREATMENT

GJS 400-15 ductile cast iron has excellent physical-chemical, mechanical-structural and manufacturability properties. However, it has notable limitations when it is subjected to the welding operations to which it is subjected. The objective of this work is the characterization of the welds made in GJS 400-15 ductile cast iron parts, specifically 6mm thick sheets, to determine their applicability based on the mechanical and microstructural properties obtained. For this, several welding procedures have been proposed, in which an Fe-Ni alloy is used as a filler material and SMAW and TIG welding techniques are combined with different heat treatments. The mechanical characterization tests have been based on tensile analysis and hardness determination. As for the micrographic analysis, it has been carried out through the micrographs of the thermally affected areas (base metal, interface and welding. TIG welding, in general terms, has been effectively effective in the welding processes of nodular cast iron sheets despite its disadvantage in the results obtained compared to the SMAW technique. On the contrary, the advantages that the TIG welding technique presents in terms of execution time and more favorable cost open a way to the development, technical evolution and industrialization of the welding processes carried out using this last technique. It is hoped that the study will present a positive contribution to the technological development of welding processes and their industrial application to the manufacture, maintenance or repair of parts and products in which ductile iron is present and especially those formed by steel plates. small thickness. Keywords: ductile cast irons welding, SMAW, TIG, heat treatments, preheating, annealing, traction, hardness, micrograph

An adaptive false-color enhancement algorithm for super-8-bit high grayscale X-ray defect image of solid rocket engine shell

The solid rocket engine is the main power unit of various missile weapons today, and it also has a wide range of applications in the aerospace field. However, in the process of welding and long-term operation, micro-invisible defects such as cracks and pores will inevitably occur inside the shell, which directly affects the performance of the solid rocket motor. This paper takes the solid engine shell X-ray film as the object. Most of the existing false-color methods are to quantize the 256-level grayscale in enhancing the image’s details. In high-level grayscale image enhancement, the grayscale loss is serious and the adaptive adjustment is not satisfactory. An adaptive false color enhancement algorithm for high-level gray-scale (super 8-bit) images is proposed. In addition, for the adaptive enhancement problem, a new method of weld locating based on the Difference of Gaussian statistics is proposed. Moreover, a new method based on the fitness function of image quality evaluation is integrated with weighted information entropy, in which PSO is improved for fast optimization. To verify the effectiveness of the method in this paper, it is applied to the visual enhancement of the low-contrast and fuzzy defect information of the solid engine shell X-ray film. The experimental results show that our design obtains the best performance on the high-level X-ray film of a solid rocket engine shell, the algorithm in this paper has greatly improved various indicators compared with the existing algorithms. The high-level false-color enhancement method is used to process the Steel Pipe Weld X-ray in small sample dataset (3408), and apply the YOLOV4 mixed training to obtain the best detection results. The method in this paper can adaptively realize the false-color enhancement of high grayscale X-ray film, with a better visual effect, which can enhance the definition of the image detail of the welding defects of the solid engine shell, and display the high grayscale image on the ordinary monitor.

Friction Stir Welding of Aluminum 7075 Alloys

Abstract: Friction Stir Welding (FSW) is a solid-state welding method which was developed by The Welding Institute and patented in 1999. The process is solid state and relies on local forging of weld region to perform weld. New welding schedules are being continuously developed for materials that are traditionally difficult to join by fusion welding methods (e.g., TIG/MIG). These experiments are performed to find out the best possible parameters to smoothly weld the aluminium 7075 alloys. By using Taguchi robust design of experiment, we selected 3 parameters namely rotation speed and transverse speed and tool shoulder diameter against the optimization function of ultimate tensile strength. The tilt angle and the plunge depth are kept constant. The variation of tensile strength is mainly due to the change in tool shoulder diameter then with welding speed and then with rotation speed. The heat generated is modelled on ANSYS software by inserting the rotation speed, coefficient of friction , material properties , radius of pin etc. The model is validated by conducting the experiment through thermocouples. The model predicted a temperature of about 410 degrees Celsius and the experimental value is 380 degrees Celsius, showing that the welding temperature is about 80% of heat generation. The Taguchi experiment consist of 4 experiments with a range of rotation speeds of 900 and 1120 respectively and a welding speed of 64mm/min and 100 mm/min respectively. The tool shoulder diameter is kept 14mm and 17mm. the welds are cut in transverse direction in order to obtain the UTS test coupon. The best possible combination is found using Taguchi Analysis. This thesis is a collection of data and response variables that correctly informs at what conditions we should weld 7075 alloy. Appropriate SN ratio is calculated and high is the best is considered as our objective function is tensile strength. Some additional tests are also performed namely hardness and microstructure and heat generation in order to identify the behaviors of aluminium alloy. Hardness and heat generated are dependent on the tool shoulder diameter then on the welding speed. This conclusion is derived from Taguchi analysis. This study is useful for the selection of parameters for the further welding operations. However, a change in plunge depth can also be taken into consideration for future scope. As tunneling defect was observed in some runs thus plunge depth has to be varied. Also, the number of experiments can be increased in order to get more refined parameters. Also, the making of base material can also be taken into consideration because of the zinc precipitate distribution. Casted AA7075 has different properties, rolled AA 7075 can have different.