An investigation into process parameters optimization for ultimate tensile strength of friction stir welded Al-10Mg-8Ce-3.5Si joint: Numerical and Design of Experiments approach

The Friction stir welding (FSW) process has become a popular method of joining metals, due to its clean and efficient nature of producing welds. The input process parameters such as tool rotation speed, tool feed and tool pin shape are the deciding parameters to get an optimum output quality characteristic such as ultimate tensile stress (UTS) of the weld joint. In this study, earlier published experimental results were used to find out optimum process parameters for UTS by applying Taguchi full factorial design technique and numerical analysis using Abaqus. A governing equation which can easily determine and maximize the UTS of the weld joint is generated. The ANOVA of means and Signal to Noise ratios for UTS were used to assess the influence of each process parameter on the output UTS. The main effect plots of the ANOVA results demonstrated that the tool rotation speed at level 1 or 800 rpm, tool feed at level 3 or 20 mm/ min and tool pin shape at level 1 or triangular cross section gave the optimum results for the output UTS. The percentage contribution of each process parameter on the UTS were investigated. Optimized process parameters to get the highest UTS were suggested.