Optimization of Friction Stir Welding Parameters of AA2014-T6 Alloy using Taguchi Statistical Approach

Abstract

In this study, the Taguchi Design of Experiment method was used to determine the optimal Friction Stir Welding (FSW) parameters for improving the mechanical properties of AA 2014-T6 alloy butt joints. The three most significant parameters-tool rotational speed, tool linear travel speed and tool tilt angle-were optimized using the L9 orthogonal array design. The optimal welding parameters for the maximum tensile strength were determined by analyzing the signal-to-noise (S/N) ratio. A regression model was developed for the desired responses. The optimal tensile strength was achieved at the 1000 rpm, rotational speed, 600 mm/rev welding speed, and 2 ° tool title angle. The results were confirmed using a steady-state heat transfer model generated from the COMSOL Multiphysics Finite Element software. The identified optimal conditions were verified by experimental validation tests. The experimental results were consistent with the predicted values. Analysis of variance (ANOVA) was conducted to determine the effects of individual parameters and to identify the most significant process parameter. ANOVA indicated that the most significant factor affecting the mechanical behavior of the joint was the tool rotation speed followed by the linear travel speed.

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Investigation of the Effect of Tool Temperature on Microstructure, Hardness, and Wear Behaviour of Aluminium 6061-T6 Alloy Welded by the Friction Stir Welding Process

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