Friction stir welding (FSW) is a solid-state welding method for the welding of aluminum alloys and has been used in aerospace, railway, automotive and marine applications. Solid-state welding processes solve several problems that occur during fusion welding of Al-alloys like HAZ liquation cracking, porosity, and segregation. Aluminum Alloys of two different series AA 5052 and AA6061 thickness of 6mm are FS welded using process parameters like tool rotational speed (900,1100,1400) rpm, transverse speed (40,50,60) mm/min, and pin profiles (cylindrical, conical, and square). This article aims to optimize the mechanical and metallurgical properties of the above dissimilar combination to evaluate the performance and characteristics of the welded joints. The combined Taguchi and Grey relation analysis experimental method was chosen to construct the number of welding experiments. The plates are successfully welded, and the welded plates are tested at room temperature to examine their tensile strength and hardness. The findings indicate that the square pin profile, the rotational speed of 1400 rpm, and the transverse speed of 40 mm/min are the optimum parameters for joining these dissimilar joints.
Machining of composite materials is accompanied by sever challenges. Fiber pullouts, fiber breakages, delamination of laminates, matrix burnings are some of the challenges, which brings significant quality and performance reductions of the product. These challenges able to be reduced with controlled or optimized machining parameters. This study investigates the optimization of cutting parameters for end milling of enset fiber reinforced epoxy composite materials to obtain optimum surface roughness and material removal rate simultaneously. The experimental runs designed based on Taguchi L9 (33 ) orthogonal arrays. The influence of cutting parameters is determined by the analysis of variance (ANOVA). Optimization is performed by coupling grey relational analysis and principal component analysis. The results revealed that depth of cut has greater contributions followed by spindle speed and feed rate respectively on the gray relational grades (GRG). The optimum values of surface roughness and material removal rate were obtained at spindle speed of 1000rpm, feed rate of 300mm/min and depth of cut of 1.5mm.
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