Optimal Design to Improve the Tensile Strength of Friction Stir Welded Dissimilar Aluminium Alloys

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Identifying optimum welding parameters for the dissimilar friction stir welding is always a challenging process due to different mechanical and thermal properties of the materials to be joined. The quality of the friction stir weld (FSW) depends upon various process parameters like welding speed, rotational speed, tool design, axial load etc.The current investigation aims in optimizing welding parameters using Taguchi design of experiments for the dissimilar   friction stir welded cast and wrought aluminum alloys A319 and AA6063 respectively. An orthogonal array of L9 (33) was used for maximizing the tensile strength by optimizing the response variables welding speed, rotation speed and tool profile. Analysis of variance was conducted to validate the results. The validated output indicates that the best quality dissimilar weld with higher tensile strength is produced at the rotational speed of 1300 rpm and welding speed of 25mm/min using square profile tool.
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Friction Stir Welding; Dissimilar Aluminium Alloys; Taguchi Method; ANOVA

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