Conference Papers
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Item Taguchi method of optimization of process variables for ultimate tensile strength of friction stir welded joint of Al-Ce-Si-Mg aluminium alloy plates(Elsevier Ltd, 2021) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.A novel method of welding known as friction stir welding or FSW has found wide applications in metal joining industries now a days. There are various process input variables which affect the output quality characteristic or response of the weld joint produced. Speed of tool rotation, tool feed and tool pin contour are important input process variables and ultimate tensile stress (UTS) of the FSW joint is the output response considered in this research. The Taguchi method of Design of Experiments type optimization was used to find the level and contribution of each of these input process variables on output quality characteristic of the FSW butt joint produced on plates of Al-Ce-Si-Mg aluminium alloy material. Taguchi L9 orthogonal array type design was utilized to bring down the number of experiments from 27 to 9 for a 3 factor, 3 levels each, analysis. The results of Taguchi analysis indicated that the speed of tool rotation at 1200 rpm, tool feed at 15 mm/min and triangular shape pin tool gave the peak output UTS. The ANOVA tests demonstrated that the contribution percentage of the tool pin contour at 41%, speed of tool rotation at 29%, and tool feed at 22%, showing that the tool pin contour has maximum bearing on the output quality characteristics, i.e., UTS of the FSW joint. The optimum UTS predicted by the Taguchi analysis was 88.29 MPa, whereas the confirmation experiments gave a result of 80.54 MPa, which was well inside the confidence interval predicted by the Taguchi design. © 2021 Elsevier Ltd. All rights reserved.Item Process parameter optimization for ultimate tensile strength of friction stir welded joint of Al-10Mg-8Ce-3.5Si aluminium alloy plates using Taguchi technique(Elsevier Ltd, 2022) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.The Friction stir welding (FSW) process has become a popular method of joining metals, due to its clean and efficient nature of producing welds. The input process parameters: the tool rotation speed, tool feed and tool pin shape are the deciding parameters for an optimum output quality characteristic, the Ultimate tensile stress (UTS) of the weld joint. Here in this research, the Taguchi full factorial design technique is discussed for maximizing the UTS of the weld joint formed in Al-10Mg-8Ce-3.5Si aluminium alloy plates. The ANOVA of means and Signal to Noise ratios for UTS was used to assess the influence of each of the input process parameters on output UTS. The main effect plots of the ANOVA results demonstrated that, the tool rotation speed at level 2 or 1000 rpm, the tool feed at level 3 or 20 mm/min and tool pin shape at level 1 or triangular cross section, gave the optimum results for output UTS. The ANOVA for UTS also showed the percentage contribution of input process parameters; the shape of tool pin as 60.06%, the tool feed as 15.42% and shape of tool pin as 2.41%. The UTS value predicted by the Taguchi analysis was at 108.47 MPa which was in good agreement with the experimentally obtained value of 106.84 MPa. A nonlinear regression equation was developed by correlating the input process parameters, which could be used to predict the optimum UTS results. © 2022 Elsevier Ltd. All rights reserved.Item A study of microstructure and mechanical properties of friction stir welded joint of Al-Ce-Si-Mg aluminium alloy plates and optimization cum prediction techniques using Taguchi and ANN(Elsevier Ltd, 2023) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.In the current research work, the effect of friction stir welding (FSW) on joint strength and evolution of microstructure at the weld zone of the friction stir welded of Al-Ce-Si-Mg aluminium alloy (Al10Mg8Ce3.5Si and Al5Mg8Ce3.5Si) is studied. The experimentations demonstrated that the speed of tool revolution, contour of tool pin and tool movement rate have influence on the quality of the FSW joint of the alloy. It was noticed that the size of grains at nugget zone (NZ) depends upon the speed of tool spin, speed, of tool feed, tool pin contour and composition of the aluminium alloy. The grain size at the bottom of the NZ was discovered to be reducing when compared to that at the top of the NZ. It was also noted that highest hardness was reached at NZ. Lowest hardness was found at heat affected zone (HAZ) and most of the tensile specimens fractured at HAZ. The Taguchi orthogonal array-based design has demonstrated that the tool pin contour had the greatest influence in enhancing the joint strength, followed by speed of tool feed, material composition and speed of tool spin. A speed of revolution of tool of 1000 rpm, tool movement rate of 20 mm/min, triangular contour pin (TCP) tool and Al10Mg8Ce3.5Si aluminium alloy were concluded as the optimum variables of the process. The percentage contribution of each one of these input process parameters on optimum output quality characteristics was also found out and noticed to be lying well within the confidence interval of 95% suggested by the Taguchi design. The current study has shown that the prediction results with artificial neural network (ANN) are better compared to those predicted using statistical methods like Taguchi Techniques. © © 2023 Elsevier Ltd. All rights reserved.