Evaluation of FSW Process Parameters of Dissimilar Aluminium Alloys

Friction stir welding (FSW) is relatively a new welding technology applied to join weldable Aluminum alloys and non- weldable Aluminum alloys that are widely used in many industrial applications such as aerospace, marine, automotive, and other industrial applications. In present research, dissimilar AA2024-T3 and AA6061-T6 Aluminum alloys of 3mm thickness was butt joined by using friction stir welding. The experimental study to optimize the welding parameters on tensile strength and bending test was carried out by Taguchi’s L9 orthogonal array. Experiments have been employed based on four welding parameters, namely, the tool traverse speed, rotational speed, tilt angle of tool and tool geometry. ANOVA technique and signal to Noise ratio were used to determine the most significant parameter that affects the mechanical properties of the weldment. X-ray radiographic, microstructure, microhardness tests have been conducted to demonstrate that samples subjected to the optimum welding parameters gave good quality and no defects have been observed. Keywords: FSW, aluminium alloys, dissimilar alloys, Taguchi Techniques, ANOVA, S/N ratio