Multi-response optimization of process parameters in friction stir welded aluminum 6061-T6 alloy using Taguchi grey relational analysis

Abstract

Purpose Friction stir welding (FSW) is considered an environmentally sound process compared to traditional fusion welding processes. It is a complex process in which various parameters influence weld strength. Therefore, it is essential to identify the best parameter settings for achieving the desired weld quality. This paper aims to investigate the multi-response optimization of process parameters of the FSWed 6061-T6 aluminum (Al) alloy. Design/methodology/approach The input process parameters related to FSW have been sorted out from a detailed literature survey. The properties of weldments such as yield strength, ultimate tensile strength, percentage elongation and microhardness have been used to evaluate weld quality. The process parameters have been optimized using the Taguchi-based grey relational analysis (GRA) methodology. Taguchi L16 orthogonal array has been considered to design the experiments. The effect of input parameters on output responses was also determined by the analysis of variance (ANOVA) method. Finally, to corroborate the results, a confirmatory experiment was carried out using the optimized parameters from the study. Findings The ANOVA result indicates that the tool rotation speed was the most significant parameter followed by tool pin profile and welding speed. From the confirmation test, it was observed that the optimum FSW process parameters predicted by the Taguchi method improved the grey relational grade by 13.52%. The experimental result also revealed that the Taguchi-based GRA method is feasible in finding solutions to multi-response optimization problems in the FSW process. Originality/value The present study is unique in the multi-response optimization of FSWed 6061-T6 Al alloy using the Taguchi and GRA methodology. The weld material having better mechanical properties is essential for the material industry.

Experimental and simulation analysis of fatigue life of aluminum 6061-T6 alloy

“…As illustrated in Figure 3, the dimensions were 190 mm long, 30 mm wide and 6 mm thick. In the case of the FSWed specimens, four different microstructure zones are found, namely, stir zone (SZ), thermo-mechanical affected zone (TMAZ), heat affected zone (HAZ) and base metal (BM) (Wang et al , 2020; Jain and Kumar, 2021). Different materials with different characteristics were used to depict different welding zones within the model.…”

“…Several studies have been published in which the fatigue life was predicted theoretically or by comparing it to experimental results (Adigio and Nangi, 2014; Singh et al , 2014; Ergenc et al , 2017; Gurubaran et al , 2017; Lesiuk et al , 2018). The ANSYS Workbench tool was also used in predicting the stress concentration areas (Jain and Kumar, 2021; Jain et al , 2013). The 3 D model, on the other hand, was created using computer-aided design (CAD) software before being integrated into the numerical software.…”

Multi-Criteria Optimisation of Friction Stir Welding Parameters for EN AW-2024-T3 Aluminium Alloy Joints

“…They concluded that the main effective parameter for the materials transfer mechanism under the pin was the welding speed. Jain and Kumar [ 36 ] conducted a multi-response optimisation of the process parameters in FSWed AW-6061-T6 aluminium alloy sheets using Taguchi grey relational analysis and ANOVA. The microhardness and UTS were used to evaluate weld quality.…”