Optimization of Input Parameters on Friction Stir Welding of Dissimilar Aluminium Alloys AA2014 and AA6061 using Taguchi Technique

Abstract

Friction stir welding holds an important position among many solid state metal joining processes which finds several applications where fusion welding methods are not suitable to form defect less welds. FSW is an innovative metal joining technique used in joining of aluminium and magnesium alloys whereas the problems encountered with conventional fusion welding were prevented. The present research is to optimize the input parameters and analyse the mechanical properties in the joining of alloys AA2014 and AA6061. The input parameters which are taken into account for this study are tool rotational speed, tool transverse speed and tool tilt angle. The experiments were being conducted according to the factorial design of experiments. After that standard size specimens were cut by EDM process from the welded joints. Tensile and hardness tests were done on the specimens and the values of ultimate tensile strength, Yield strength, % of Elongation and Vickers Hardness number were measured. By finding the signal to noise ratio the optimum input parameters were identified. The values are 560rpm, 100mm/min and 2 degrees respectively. The importance of each input parameter was evaluated by ANOVA method which indicates that the parameter tool tilt angle is having higher contribution of 38.73%.