Taguchi analysis of friction stir welded 5754 H111 aluminum alloy with 7075 T651 interlayer material

Abstract

Abstract The goal of this research is to improve the ultimate tensile strength (UTS) of welded AA5754 H111 aluminum alloy joints with a 7075 T651 interlayer by enhancing the Friction Stir Welding (FSW) process parameters. The investigation employs the Taguchi approach to examine the effects of three important parameters: interlayer thickness (0.8, 1.0, 1.2 mm), welding speed (30, 40, 50 mm/min), and tool rotational speed (750, 850, 950 rpm). The primary characteristic, based on ANOVA analysis, was tool rotational speed (F-value: 329.59, p-value: 0.000). Welding speed (F-value: 26.52) and interlayer thickness (F-value: 19.05). For the experiment to attain a tensile strength of 185.96 MPa with a minimal error of 0.96 MPa (0.52%) from the desired value, the optimal procedure parameters were found to be 950 rpm tool rotating speed, 40 mm/min welding speed, and 0.8 mm interlayer thickness. With an R-squared value of 98.68%, surface plots and residual analysis validated the regression model's correctness and dependability. Through the implementation of interlayer materials and experimental optimization techniques, this research yields important insights into optimizing the mechanical properties of FSW joints.