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

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Authors

  • Pratap Kumar J
     Research Scholar, Department of Mechanical and Automobile Engineering, School of Engineering and Technology, CHRIST (Deemed to be University), Bengaluru 560074, Karnataka ,IN
  • Anil Raj
     Assistant Professor, Department of Mechanical and Automobile Engineering School of Engineering and Technology, CHRIST (Deemed to be University), Bengaluru 560074, Karnataka ,IN
  • Ramesha K
     Assistant Professor, Department of Mechanical and Automobile Engineering School of Engineering and Technology, CHRIST (Deemed to be University), Bengaluru 560074, Karnataka ,IN
  • Ivan Sunit Rout
     Assistant Professor, Department of Mechanical and Automobile Engineering School of Engineering and Technology, CHRIST (Deemed to be University), Bengaluru 560074, Karnataka ,IN

DOI:

https://doi.org/10.18311/jmmf/2022/32029

Keywords:

Friction stir welding; Hardened OHNS steel tool; tool pin offset; Taguchi L9 orthogonal array; ANOVA

Abstract

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.

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Published

2022-12-08

How to Cite

Kumar J, P., Raj, A., K, R., & Rout, I. S. (2022). Design and Optimization of Friction Stir Welding of Al-Cu BUTT Joint Configuration using Taguchi Method. Journal of Mines, Metals and Fuels, 70(8A), 471–479. https://doi.org/10.18311/jmmf/2022/32029

Issue

Volume 70, Issue 8A, August 2022

Section

Articles

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Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

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