Optimizing the process parameters of Fiction Stir Welded dissimilar 2024Al-5754Al Joint using the Taguchi Method

Abstract

It is a requirement of modern age industries, especially the aerospace, automobile, and shipbuilding sectors, to manufacture high strength and low weight dissimilar aluminium alloy welded joints. Therefore, the aim of this project is to investigate the effect of tool rotation speed, feed rate, and pin type on the ultimate tensile strength (UTS) of dissimilar aluminium alloys (2024 Al and 5754 Al) in friction stir welded joints. Nine experiments have been performed using an orthogonal array (L9) of the Taguchi method. An analysis of variance (ANOVA) established that pin type is the most prominent parameter, followed by tool rotation speed and feed rate. The optimal value of ultimate tensile strength (268 MPa) was achieved at 1.5 mm/s feed rate, 1600 rpm speed, and type 1 of pin. A confirmation test shows that there is a high correlation between the estimated and actual values of UTS.

Keywords

• ultimate tensile strength
• friction stir welded joints
• taguchi method
• 2024al-5754al
• orthogonal array