FSW Process Constrain to Attain Extreme Tensile Strength of Aluminum Alloy 6061

Abstract

This paper reports on an examination of the effect and optimization of welding parameters on the tensile shear strength in Friction Stir Welding process. The experimental test readings were conducted under varying Tool Rotation Speed (rpm), Tool Traveling Speed (mm/min), and Tool Tilt Angle (degree). The settings of welding parameters were determined by using the Taguchi experimental design method. Experiments were conducted on AA6061 Aluminium alloy in a Vertical Machining Machine Centre. The output factors are measured in UTM. Results show strong relation and robust comparison between the weldment strength and process parameters. Hence FSW process variable data base is to be developed for wide variety of metals and alloys for selection of optimum process parameters for efficient weld. The level of importance of the welding parameters on the tensile shear strength is determined by using analysis of variance (ANOVA). The optimum welding parameter combination was found by using the analysis of signal-to-noise (S/N) ratio. The validation tests indicated that it is possible to increase tensile shear strength significantly by using the Taguchi method. The experimental results confirmed the validity of the used Taguchi method for enhancing the welding performance and improving the welding parameters in the Linear Friction Stir welding process.