Friction Stir Welding Process Parameters Optimization By Taguchi Analysis and Validating The Mathematical Model Using RSM For AA6101-C11000 Alloy Joints
- Title
- Friction Stir Welding Process Parameters Optimization By Taguchi Analysis and Validating The Mathematical Model Using RSM For AA6101-C11000 Alloy Joints
- Creator
- Pratap Kumar, J
- Contributor
- Anil, Raj
- Description
- Friction Stir Welding (FSW) is a well-established joining method that offers newlinesignificant advantages over traditional methods, including improved mechanical newlinecharacteristics, less distortion, and environmental friendliness. Due to its solid-state nature, the heat produced through the welding mainly influences the features of joints in FSW. In this investigation, 2D and 3D models of the base metals and welding tool newlinewith different pin profiles were designed using SOLIDWORKS. Fixture was designed and manufactured in accordance with the specifications of the welding machine. ANSYS software was used to investigate the temperature distributions near the weld newlinezones. The base metals AA6101 and C11000 of each 5 mm thickness with butt weld newlinepositioned, were joined by FSW mechanism with the help of OHNS steel tool with circular pin profile. Taguchi analysis was employed to optimize the FSW welding input process parameters, including tool rotational speed (rpm), feed rate (mm/min), and tool offset (mm), to determine their respective contribution (%) to the output response, namely ultimate tensile strength (UTS), hardness, impact load, and electrical newlineconductivity to achieve the high joint strength. During experimental work using the newlineTaguchi s design matrix, the maximum output response values were obtained when the input parameters were set to 1000 rpm, 50 mm/min and -1 mm. Taguchi analysis revealed that the tool rotational speed encounters high significance effects, followed by feed rate and least tool offset upon output response. The X-ray diffractometer (XRD) test was employed to specifically determine the existence of Al-Cu intermetallic compounds (IMCs) generated within the FSW of Al (AA6101) and Cu (C11000) joints. At medium 40 mm/min, 1000 rpm, and -1.68 mm, the IMCs newlinedeveloped were Al4Cu9 and Al1Cu3 giving a high UTS value of about 142.69 MPa. newlineMathematical model was developed utilizing the Response Surface Method (RSM) to newlinepredict the output response.
- Source
- Author's Submission
- Date
- 2024-01-01
- Publisher
- Christ(Deemed to be University)
- Subject
- Mechanical and Automobile Engineering
- Rights
- Open Access
- Relation
- 61000365
- Format
- Language
- English
- Type
- PhD
- Identifier
- http://hdl.handle.net/10603/585928
Collection
Citation
Pratap Kumar, J, “Friction Stir Welding Process Parameters Optimization By Taguchi Analysis and Validating The Mathematical Model Using RSM For AA6101-C11000 Alloy Joints,” CHRIST (Deemed To Be University) Institutional Repository, accessed February 23, 2025, https://archives.christuniversity.in/items/show/12411.