Multi-objective optimization of high carbon steel (EN-31) and low carbon steel (SAE-1020) using Grey Taguchi method in rotary friction stir welding

Abstract

Purpose Nowadays, a rotary friction welding method is accepted in many industries, particularly for joining dissimilar materials as a mass production process. It is due to advantages like less material waste, low production time and low energy expenditure. The effect of the change in carbon contents in steel is studied experimentally in the rotary friction welding process, and a statistical model is developed. The Grey Taguchi method gives the single parameters optimization for all output responses. The paper aims to discuss these issues. Design/methodology/approach An experimental setup was designed and produced to achieve the multi-response in single optimum parameters through Grey relational analysis. A continuous/direct drive rotary friction welding process is chosen in which transition from friction to the forging stage can be achieved automatically by applying a break. In this experimentation, high carbon and low carbon work-pieces with different carbon percentage were welded with rotary friction welding. Response tensile strength and micro-hardness of the design of the experiment are used to analyze the results. Findings The optimization of parameters has been performed with Grey relational analysis, and optimum parameters are friction pressure 40 kg/cm2, forging pressure 100 kg/cm2 and speed 1,120 rpm. GRA optimum parameters give 56.04 and 82.16 percent improvement in Tensile strength and micro-hardness, respectively. Practical implications High carbon steel (En-31) and low carbon steel (SAE-1020) are used in so many industrial applications. These materials are mostly used in the process like manufacturing, metallurgy, machinery, agricultural, etc. These practical applications have brought forward definite and notable economic benefits. Originality/value It provides a new framework to investigate the problems where multiple input machining variables and various output responses are obtained in single optimized parameters.

Microstructural Characterization and Corrosion Behavior of Similar and Dissimilar Welded Advanced High-Strength Steels (AHSS) by Rotary Friction Welding

“…RFW was initially developed by the extinct Soviet Union [5], where the first experiments date back to 1956 and resulted in several patents. In addition, major American companies, such as Caterpillar, Rockwell International, and the American Manufacturing Foundry, developed equipment and machinery for this process [5].…”

“…RFW was initially developed by the extinct Soviet Union [5], where the first experiments date back to 1956 and resulted in several patents. In addition, major American companies, such as Caterpillar, Rockwell International, and the American Manufacturing Foundry, developed equipment and machinery for this process [5]. From that time until today, many research works have been carried out, focusing their efforts on understanding both the effect of the welding parameters and the involved phenomena that take place as a consequence of the thermomechanical cycle applied to achieve the welding and its influence on the mechanical properties of the joined materials.…”

Optimization of joining HDPE rods by continuous drive friction welding

“…Some researchers implemented experimental designs to determine significant process parameters or levels or optimize the process. Most statistical experimental design studies consider using Taguchi analysis [10,[20][21][22]. Response surface method (RSM) offers a robust experimental design procedure.…”