Identifying the Optimal Process Parameter on AA1100 Friction Stir Welded Joints

Abstract

In this work butt joints were made on AA1100 aluminum alloy using Friction stir welding technique. To obtain strongly bonded weld, the process parameters like profile of tool pin (Cylindrical and threaded tool profile), feed rate of table, inclination of tool, and tool rotation were selected. The parameters thus selected were taken in various levels and in different combinations.The experiments were conducted as per Taguchi L18 mixed orthogonal array design. The process parameters were optimized using Grey Relational Analysis. The optimum process parameters were obtained while using threaded profile with 1200 rpm, tool speed 25 mm/min, movement of the table with 2° tool angle. For this optimized combination, the weld zone produced a maximum of 92.9% of tensile strength, 50.8% of elongation and 91.6% of hardness values compared with the values of the properties of the base material. ANOVA shows that welding speed is a more dominant factor due to the increasing frictional heat generation as well as flow properties of materials in stirred zone.