Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology

This study presents the effect of the governing parameters in friction stir welding (FSW) on the mechanical properties and weld quality of a 6mm thick 6061 T651 Aluminum alloy butt joint. The main FSW parameters, the rotational and traverse speed were optimized based on multiple mechanical properties and quality features, which focus on the tensile strength, hardness and the weld quality class using the multi-objective Taguchi method (MTM). Multi signal to noise ratio (MSNR) was employed to determine the optimum welding parameters for MTM while further analysis concerning the significant level determination was accomplished via the well-established analysis of variance (ANOVA). Furthermore, the first order model for predicting the mechanical properties and weld quality class is derived by applying response surface methodology (RSM). Based on the experimental confirmation test, the proposed method can effectively estimate the mechanical properties and weld quality class which can be used to enhance the welding performance in FSW or other applications.

[1]  Jiju Antony,et al.  Simultaneous Optimisation of Multiple Quality Characteristics in Manufacturing Processes Using Taguchi's Quality Loss Function , 2001 .

[2]  Roseleena Jaafar,et al.  Model development for quality features of resistance spot welding using multi-objective Taguchi method and response surface methodology , 2013, J. Intell. Manuf..

[3]  Şefika Kasman.  Erratum to: Multi-response optimization using the Taguchi-based grey relational analysis: a case study for dissimilar friction stir butt welding of AA6082-T6/AA5754-H111 , 2013 .

[4]  Vinod Yadava,et al.  Experimental modeling and multi-objective optimization of traveling wire electrochemical spark machining (TW-ECSM) process , 2013 .

[5]  Muhammad Qaiser Saleem,et al.  Parametric optimization for surface roughness, kerf and MRR in wire electrical discharge machining (WEDM) using Taguchi design of experiment , 2013 .

[6]  V. Gunaraj,et al.  Application of response surface methodology for predicting weld bead quality in submerged arc welding of pipes , 1999 .

[7]  Ghalib Tham,et al.  Optimization and modeling of spot welding parameters with simultaneous multiple response consideration using multi-objective Taguchi method and RSM , 2012 .

[8]  V. Balasubramanian,et al.  Predicting tensile strength of friction stir welded AA6061 aluminium alloy joints by a mathematical model , 2009 .

[9]  P. S. Satsangi,et al.  Multiple-response optimization of turning machining by the taguchi method and the utility concept using uni-directional glass fiber-reinforced plastic composite and carbide (k10) cutting tool , 2013 .

[10]  R. Subramanian,et al.  Influence of graphite and machining parameters on the surface roughness of Al-fly ash/graphite hybrid composite: a Taguchi approach , 2013 .

[11]  M. Koilraj,et al.  Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 – Optimization of process parameters using Taguchi technique , 2012 .

[12]  R. M. Leal,et al.  Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds , 2009 .

[13]  Z. Ma,et al.  Effect of welding parameters on tensile properties and fracture behavior of friction stir welded Al-Mg-Si alloy , 2007 .

[14]  V. Yadava,et al.  Multi-objective optimisation of laser beam cutting process , 2008 .

[15]  V. Balasubramanian,et al.  Optimization of process parameters for friction stir welding of cast aluminium alloy A319 by Taguchi method , 2009 .

[16]  Abdul-Ghani Olabi,et al.  Optimization of tensile strength of ferritic/austenitic laser-welded components , 2008 .

[17]  G. Venkateswarlu,et al.  Taguchi Optimisation of Friction Stir Processing Parameters to Achieve Maximum Tensile Strength of Mg AZ31B Alloy , 2012, Transactions of the Indian Institute of Metals.

[18]  Virgínia Infante,et al.  Optimization of FS Welding Parameters for Improving Mechanical Behavior of AA2024-T351 Joints Based on Taguchi Method , 2013, Journal of Materials Engineering and Performance.

[19]  Sangshik Kim,et al.  Tensile behavior of friction-stri-welded Al 6061-T651 , 2004 .

[20]  J. Bunyan,et al.  Application Of Taguchi Technique For Friction Stir Welding Of Aluminum Alloy AA6061 , 2013 .