Improving process quality in friction welding for bimetal lugs

The purpose of this study is to investigate the effect of process parameter settings on quality of bimetal lugs produced by friction welding process. The study was conducted in a local electrical power components manufacturer. The company faced high reject rates of bimetal lugs. To avoid disturbance to the actual production line, the relevant historical process data were extracted and analysed. The data were mapped into full factorial experimental design matrix. The significance of operating parameters, namely, the rotational speed, friction pressure and friction time were investigated. The data analysis reveals the recommended optimum setting should berotational speed at high level (1450 Rpm), friction pressure at low level (39.2 Pa) and friction time at low level (4 s). The first order models are also proposed for prediction of the responsestensile strength, upset and temperature