Selection of best process parameters for friction stir welded dissimilar Al-Cu alloy: a novel MCDM amalgamated MORSM approach

Abstract

The paper focuses on developing a novel decision-making model, to select the best welding parameters for friction stir welding of dissimilar aluminium to copper plates. A set of 21 experiments are carried out based on a d-optimal design matrix. Apart from considering the rotational speed and traverse speed as input variables, the position of aluminium and copper either in the advancing or retreating side is also considered as an input variable. On the successful fabrication of joints, the ultimate tensile strength, elongation, hardness and impact energy are estimated experimentally which are considered as performance parameters. The proposed decision-making process is categorized under multi-criteria decision-making (MCDM) methods. In the first phase, the novel MCDM model is applied to select the best welding parameters. The concept of the model is to minimize the risk of not attaining the global best result. The results obtained by the MCDM method is justified by carrying out a sensitivity analysis and finally validated with the results obtained from the fuzzy logic decision-making approach. The second phase is related to the computation of optimized values for the joining process that reports the development of a mathematical model by response surface methodology to predict different performance parameters. This is followed by conducting a trade-off analysis by developing a multi-objective response surface methodology (MORSM) that computes the optimal welding parameters. Finally, a confirmatory test is carried out for validation of the proposed MORSM model.

Variable Neighborhood Strategy Adaptive Search for Optimal Parameters of SSM-ADC 12 Aluminum Friction Stir Welding

“…We used 12 test examples collected from the literature [15,28,33,[71][72][73][74][75][76][77][78][79]. We identified the optimal parameters using the proposed methods and compared these with the results obtained using the D-optimal/RSM approaches on the aforementioned literature.…”

Parametric Optimisation of Friction-Stir-Spot-Welded Al 6061-T6 Incorporated with Silicon Carbide Using a Hybrid WASPAS–Taguchi Technique

“…The level of significance considered for ANOVA was 5%, i.e., 95% confidence level. Moreover, ANOVA provided a clear vision of how the process parameters influenced the response, along with their level of significance [22,33,34]. Meanwhile, the relative power of each factor was indicated by the percentage contribution of each parameter, which is a function of sum of squares, in order to reduce the disparity in the experimental results.…”

“…Hence, optimisation of parameters is necessary to simplify the selection of parameters to obtain improved results. Therefore, various mathematical and statistical models have been developed in order to reduce the human resources and time consumed during experimentation [22]. Acharya et al [23] welded dissimilar materials using FSSW and optimised the process parameters using the Taguchi method.…”

Optimization of friction stir welding AA6082-T6 parameters using analysis of variance and grey relational analysis

“…Particularly, it can be used for welding aerospace aluminum alloys and other materials such as stainless steel, titanium, and high-strength steel, which are difficult to weld by conventional fusion welding processes. FSW prevents melting, cast microstructure formation, and solidifying weld shrink zone found in traditional fusion welding [2]. The FSW process schematic diagram is shown in figure 1.…”

“…Tensile strength, surface roughness, hardness, microstructure, impact strength, etc., all influence the quality of a weld. As a result, it is critical to evaluate the parameters' influence on weld quality attributes [2]. [7] investigated the FSW parameters' influence on nugget zone hardness, UTS, and temperature distribution of welded T-joints of AA6063-T6.…”