Optimization of FSW process parameters for maximum UTS of AA6061/rutile composites using Taguchi technique

Abstract

In the friction stir welding process, preferred joint property is vastly reliant on the selection of optimal welding conditions. The present study aims to use the Taguchi technique to find the optimal process conditions for achieving superior Ultimate Tensile Strength (UTS) in friction stir welded Aluminum Matrix Composite (AMC) joints. AMCs reinforced with rutile particles which have a potential application in the aerospace, automotive, and marine industries are used in the present work. Taguchi parametric design technique was used to identify the effect of rotational speed, tool traverse speed, and tool geometry on joint strength. Taguchi approach confined the optimum level of process variables and these variables were optimized. The investigation showed that the parameters within the selected value range will seriously affect the output. The predicted value of the output response was 155.48 MPa, which was validated by further experiments using the optimum process variables. Analysis Of Variance (ANOVA) results indicated that the UTS of the composite joint is mainly affected by the tool traverse speed followed by rotational speed, and tool geometry. The microstructural study unveiled that grain size is dependent on process variables and finer grains offer better joint properties. © 2022 Sharif University of Technology. All rights reserved.