Process Parameters Optimization for Friction Stir Welding of Pure Aluminium to Brass (CuZn30) using Taguchi Technique

In this research, the friction stir welding of dissimilar commercial pure aluminium and brass (CuZn30) plates was investigated and the process parameters were optimized using Taguchi L9 orthogonal array. The considered process parameters were the rotational speed, traverse speed and pin offset. The optimum setting was determined with reference to ultimate tensile strength of the joint. The predicted optimum value of ultimate tensile strength was confirmed by experimental run using optimum parameters. Analysis of variance revealed that traverse speed is the most significant factor in controlling the joint tensile strength and pin offset also plays a significant role. In this investigation, the optimum tensile strength is 50% of aluminium base metal. Metallographic examination revealed that intermetallic compounds were formed in the interface of the optimum joint where the tensile failure was observed to take place.