Process parameter optimization for FSW of AA6061/SiC/fly ash AMCs using Taguchi technique

Abstract

In this research work, aluminum matrix composite (AMC) plates were welded using friction stir welding (FSW). AMCs contain AA6061 as a base metal with silicon carbide (SiC) and fly ash particles as reinforcements. The FSW process parameters considered in this work were tool rotational speed (revolutions/minute), tool traverse speed (millimeters/minute) and tool tilt angle (degrees). The Taguchi L<inf>9</inf> orthogonal array was considered for optimizing the process parameters. Tensile strength and hardness were the two output responses obtained by analyzing joint efficiency and signal/noise ratio. An analysis of variance (Anova) study was conducted to identify the percentage contribution of each process parameter to the output responses. The Anova study concluded that among the three process parameters, tool rotational speed was the most dominant parameter in deciding the tensile strength and hardness of the FSW joints, followed by traverse speed and tool tilt angle. At the end, the results were validated by conducting additional experiments. © 2018 ICE Publishing: All rights reserved.