Optimization of Process Parameters for Friction Stir Welding of Aluminium Alloy AA5052-H32 by Using Taguchi Method

Abstract

This research interacts with the impact on ultimate tensile strength in FSW operation of controllable variables, especially rotational speed of tool, table speed, and shoulder diameter. The experiments were performed through the Taguchi approach on a 3 mm thick AA5052-H32 aluminium alloy sheet. The welded joints were distinguished by their morphology, mechanical properties (tensile strength and microhardness), and microstructural characteristics. “A three-level, three-factor experimental design was carried out using Minitab software in accordance with TaguchiL9 array to determine the most significant variable and % participation of the specific tensile strength variable,analysis of ANOVA, and ratio of signal to noise (S/N)”. As a result, the optimal level for tensile strength was identified to be 1000 rpm of rotational speed of tool, 40 mm/min of table movement, and 12 mm of tool shoulder diameter. Weld joints had a higher tensile strength of 180.12 MPa at 1000 rpm of rotational speed and 40 mm/min of table movement, which was about 79% of the base Al alloy strength. Research on microstructure reveals that the grain size becomes lower in weld stir region than base Al alloy, as well as nugget region will have a significantly higher hardness than base aluminium alloy. As a result, with a contribution of 71.84%, welding speed seems to be the significant contributing factor. © 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.