Optimization of Process Parameters for Friction Stir Welding of Aluminum and Copper Using the Taguchi Method

Abstract

Producing joints of aluminum and copper by means of fusion welding is a challenging task. However, the results of various studies have proven the potential of friction stir welding (FSW) for manufacturing aluminum-copper joints. Despite the proven feasibility, there is currently no series application in automotive industry to produce aluminum-copper joints for electrical contacts by means of FSW. To make FSW as efficient as possible for large-scale production, maximized welding speed is desired. Taking this into account, this paper presents results of a parametric investigation, the objective of which was to increase the welding speed for FSW of aluminum and copper in comparison to welding speeds that are considered to be state of the art. Taguchi method was used to design an experimental plan and target figures of the investigations were the resultant tensile strengths and electrical resistances. Dependencies between input parameters and target figures were determined systematically. The optimal welding parameters, at which joints failed in the weaker aluminum material, included a welding speed of 700 mm/min. Consequently, it could be shown that joints with a performance similar to those of the base materials can be obtained using significantly higher welding speeds than reported in the relevant literature.

Selection of best process parameters for friction stir welded dissimilar Al-Cu alloy: a novel MCDM amalgamated MORSM approach

“…Subsequently, metallurgical and mechanical tests were carried out for the optimized parameters. Eslami et al utilized a fractional factorial Taguchi L25 design in order to maximize welding speed at which the highest strength and lowest electrical resistance are obtained [23]. The method adopted was successfully able to predict a traverse speed of 700 mm/min that was significantly higher than values that have been reported in available studies.…”

Microstructural, mechanical and tribological characterization on the Al based functionally graded material fabricated powder metallurgy

“…Therefore, the optimization of material composition and fabrication parameters is vital before the machining process and FGM fabrication. Taguchi [24] and ANOVA [25] are prominently utilized optimization techniques, in which the exact optimum point can be determined.…”

Effect of Process Parameters on Interfacial Bonding Properties of Aluminium–Copper Clad Sheet Processed by Multi-Pass Friction Stir-Welding Technique

“…Cu alloy is a relatively expensive material with a higher density compared with Al alloy [5]. Therefore, industries often substitute Cu-based components with Al to reduce overhead costs [6,7]. The full substitution of Cu with Al is not feasible for most industrial applications because it affects the overall manufacturing; thus, the fabrication of Cu-Al joints in related industries is in high demand [8,9].…”