Parameter Optimization and Tensile Strength Prediction of Friction Stir Welding of AA 6061 Aluminium using Taguchi Technique

Friction stir welding (FSW) is emerging as a green solid-state joining process to weld low melting point alloys with specific advantages. The quality of welds formed are good due to the absence of melting of parent metal, eliminating post cleaning operations. Selection of optimum process parameters play a vital role in FSW process. In this work tensile strength of aluminium friction stir welds are investigated at room temperature by varying tool rotating speed, tool traverse feed and axial force. The settings of process parameters were determined by using Taguchi’s experimental design method. The degrees of influence of each process parameter were studied and the optimal values that maximize tensile strength determined. An empirical relationship between tensile strength and input parameters was formulated. As AA 6061 is one of the strongest aluminium alloys in industrial use today; the revelation made in this research would significantly contribute to the optimization of welding parameters