Abstract
This study presents the effect of the governing parameters in friction stir welding (FSW) on the mechanical properties and weld quality of a 6mm thick 6061 T651 Aluminum alloy butt joint. The main FSW parameters, the rotational and traverse speed were optimized based on multiple mechanical properties and quality features, which focus on the tensile strength, hardness and the weld quality class using the multi-objective Taguchi method (MTM). Multi signal to noise ratio (MSNR) was employed to determine the optimum welding parameters for MTM while further analysis concerning the significant level determination was accomplished via the well-established analysis of variance (ANOVA). Furthermore, the first order model for predicting the mechanical properties and weld quality class is derived by applying response surface methodology (RSM). Based on the experimental confirmation test, the proposed method can effectively estimate the mechanical properties and weld quality class which can be used to enhance the welding performance in FSW or other applications.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
K. Elangovan, V. Balasubramanian and S. Babu, Predicting tensile strength of friction stir welded AA6061 aluminium alloy joints by a mathematical model, Materials & Design, 30 (1) (2009) 188–193.
M. Jayaraman, R. Sivasubramanian, V. Balasubramanian, and A. K. Lakshminarayanan, Optimization of process parameters for friction stir welding of cast aluminium alloy A319 by Taguchi method, Journal of Scientific & Industrial Research, 68 January (2009) 36–43.
D. M. Rodrigues, A. Loureiro, C. Leitao, R. M. Leal, B. M. Chaparro and P. Vilaça, Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds, Materials & Design, 30 (6) (2009) 1913–1921.
S. Lim, S. Kim, C. Lee and S. Kim, Tensile behaviour of friction stir welded Al 6061-T651, Metallurgical and Materials Transactions A, 35 (2004) 2829–2835.
S. R. Ren, Z. Y. Ma and L. Q. Chen, Effect of welding parameters on tensile properties and fracture behavior of friction stir welded Al-Mg-Si alloy, Scripta Materialia, 56 (1) (2007) 69–72.
N. Muhammad, Y. H. P. Manurung, R. Jaafar, S. K. Abas, G. Tham and E. Haruman, Model development for quality features of resistance spot welding using multi-objective Taguchi method and response surface methodology, Journal of Intelligent Manufacturing, 24 (6) (2012) 1175–1183.
G. Chand and J. Bunyan, Application of taguchi technique for friction stir welding of aluminum alloy AA6061, International Journal of Engineering Research & Technology, 2 (2013) 409–413.
M. Koilraj, V. Sundareswaran, S. Vijayan and S. R. K. Rao, Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 — Optimization of process parameters using Taguchi technique, Materials & Design, 42 (2012) 1–7.
E. M. Anawa and A. G. Olabi, Optimization of tensile strength of ferritic/austenitic laser welded component, Optic and Laser in Engineering, 46 (2008) 571–577.
V. Gunaraj and N. Murugan, Application of response surface methodology for predicting weld bead quality in submerged arc welding of pipes, Journal of Materials and Processing Technology, 88 (1999) 266–275.
A. K. Dubey and V. Yadava, Multi-objective optimisation of laser beam cutting process, Optics & Laser Technology, 40 (2008) 562–570.
S. Fraley, M. Oom, B. Terrien and J. Z. Date, Design of experiments via Taguchi methods:orthogonal arrays, The Michigan Chemical Process Dynamic and Controls Open Text Book, USA (2006).
N. Muhammad, Y. H. P. Manurung, M. Hafidzi, S. K. Abas, G. Tham and E. Haruman, Optimization and modeling of spot welding parameters with simultaneous multiple response consideration using multi-objective Taguchi method and RSM, Journal of Mechanical Science and Technology, 26 (8) (2012) 2365–2370.
A. Ikram, N. A. Mufti, M. Q. Saleem and A. R. Khan, Parametric optimization for surface roughness, kerf and MRR in wire electrical discharge machining (WEDM) using Taguchi design of experiment, Journal of Mechanical Science and Technology, 27 (7) (2013) 2133–2141.
C. Vidal and V. Infante, Optimization of FS welding parameters for improving mechanical behavior of AA2024-T351 joints based on Taguchi method, Journal of Materials Engineering and Performance, 22 (2013) 2261–2270.
G. Venkateswarlu, M. J. Davidson and G. R. N. Tagore, Taguchi optimisation of friction stir processing parameters to achieve maximum tensile strength of Mg AZ31B Alloy, Transactions of the Indian Institute of Metals, 65 (5) (2012) 491–496.
S. Kasman, Multi-response optimization using the taguchi-based grey relational analysis: a case study for dissimilar friction stir butt welding of AA6082-T6/AA5754-H111, The International Journal of Advanced Manufacturing Technology, 68 (1–4) (2013) 795–804.
N. Muhammad, Y. H. P. Manurung, R. Jaafar, S. K. Abas, G. Tham and E. Haruman, Model development for quality features of resistance spot welding using multi-objective Taguchi method and response surface methodology, Journal of Intelligent Manufacturing, 24 (6) (2012) 1175–1183.
J. Antony, Simultaneous ootimisation of multiple quality characteristics in manufacturing processes using Taguchi’s Quality Loss Function, Int. Journal Adv. Manufacturing Technology, 17 (2001) 134–138.
B. K. Bhuyan and V. Yadava, Experimental modeling and multi-objective optimization of traveling wire electrochemical spark machining (TW-ECSM) process, Journal of Mechanical Science and Technology, 27 (8) (2013) 2467–2476.
P. Shanmughasundaram and R. Subramanian, Influence of graphite and machining parameters on the surface roughness of Al-fly ash/graphite hybrid composite: a Taguchi approach, Journal of Mechanical Science and Technology, 27 (8) (2013) 2445–2455.
S. Kumar, Meenu and P. S. Satsangi, Multiple-response optimization of turning machining by the taguchi method and the utility concept using uni-directional glass fiberreinforced plastic composite and carbide (k10) cutting tool, Journal of Mechanical Science and Technology, 27 (9) (2013) 2829–2837.
Author information
Authors and Affiliations
Corresponding author
Additional information
Recommended by Associate Editor Young Whan Park
Yupiter HP Manurung is currently an Associate Professor at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his BSc. in Manufacturing Technology from University of Applied Sciences GSO Nueremberg, Germany and his MSc. As well as Ph.D. in Manufacturing Technology from University O-v-G Magdeburg, Germany. He also obtained International/European/German Welding Engineer (IWE/EWE/SFI) from SLV Halle, Germany and Laser Technology from University Jena, Germany. His research interests include Advanced Manufacturing Technology and Simulation, Advanced Welding Technology and Simulation and Quality & Reliability Engineering.
Mohamed Ackiel Mohamed is currently a Ph.D.’s student in Mechanical Engineering at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his B. Eng (Hons) in Mechanical Engineering in 2012. He is also attached as a Specialist in the Fabrication and Joining Section in University Kuala Lumpur Malaysia France Institute (UNIKL MFI), Malaysia as well as being a qualified welding inspector with CSWIP 3.0 and 3.1 qualifications.
Mohamed Nor Berhan is a professor in materials engineering in the Faculty of Mechanical Engineering Universiti Tek- nologi Mara, Shah Alam Selangor. He has been involved in research activities related to materials such as failure analysis for metals and composites, materials development and characterization as well as hybrid materials development since his post graduate days in 1989. Prof. M. N. Berhan has also won few awards for his works such as the best Award from The Malaysian Association of Research Scientist and the ITEX Award.
Rights and permissions
About this article
Cite this article
Mohamed, M.A., Manurung, Y.H.P. & Berhan, M.N. Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology. J Mech Sci Technol 29, 2323–2331 (2015). https://doi.org/10.1007/s12206-015-0527-x
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12206-015-0527-x