Optimization of FSW process parameters for maximum UTS of AA6061/rutile composites using Taguchi technique

In the friction stir welding process, preferred joint property is vastly reliant on the selection of optimal welding conditions. The present study aims at the application of the Taguchi approach to finding out the optimal process conditions to get superior ultimate tensile strength in the friction stir welded aluminium matrix composite (AMC) joints. AMC reinforced with rutile particles which have a potential application in the aerospace, automotive, and marine industries are used in the present work. Taguchi parametric design technique was used to identify the influence of rotational speed, tool traverse speed, and tool geometry on joint strength. Taguchi approach confines the optimum level of process variables and optimization of these variables was performed based on this study. Investigation reveals that the parameters within the chosen range of values, critically affect the output. The predicted value of the output response is 155.48 MPa which was validated by conducting further trials with optimum process variables. ANOVA results indicated that the UTS of the composite joint is mainly affected by the tool traverse speed followed by rotational speed, and tool geometry. The microstructural study unveiled that grain size is dependent on process variables and finer grains offer better joint properties