A multi-objective optimization of the friction stir welding process using RSM-based-desirability function approach for j
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RESEARCH PAPER
A multi-objective optimization of the friction stir welding process using RSM-based-desirability function approach for joining aluminum alloy 6063-T6 pipes S. M. Senthil 1
&
R. Parameshwaran 2 & S. Ragu Nathan 3 & M. Bhuvanesh Kumar 1 & K. Deepandurai 1
Received: 10 October 2019 / Revised: 8 December 2019 / Accepted: 10 February 2020 # Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract In this study, a multi-objective optimization technique involving response surface methodology (RSM)-based desirability function approach is used in optimizing the process parameters for friction stir welding of AA6063-T6 pipes. Two process parameters, namely, tool rotational speed and weld speed, are optimized for achieving a weld joint having superior tensile properties, viz., maximum yield, and ultimate tensile strength and maximum % of elongation. A regression model, with a 95% confidence level, is developed using response surface methodology to predict the tensile strength of the weld joint. ANOVA technique is used to determine the adequacy of the developed model and identify the significant terms. The desirability function is used to analyze the responses and predict the optimal process parameters. It is found that tool rotational speed and weld speed have equal influence over the tensile strength of the pipe weld. Tool rotational speed 1986 rpm and weld speed 0.65 rpm have yielded a maximum ultimate tensile strength of 167 MPa, yield strength of 145 MPa, and % elongation of 8.3, under considered operating conditions. Microstructural attributes for superior weld properties are also discussed. Keywords Aluminum pipe . FSW . Optimization . RSM . Desirability function . Tensile strength
1 Introduction Joining pipes using friction stir welding (FSW) process is taking shape from the laboratory research level. The delivery of high weld strength is one of the significant advantages of the FSW process, whose choices and ranges are being exploited through rigorous research activities since its inception. Pipe joining technology usually involves fusion welding techniques in which many distortions take place, making it prone to defects/failures. Now, researchers are working for the Responsible Editor: Ren-Jye Yang * S. M. Senthil [email protected] 1
Department of Mechanical Engineering, Kongu Engineering College, Erode, India
2
Department of Mechatronics Engineering, Kongu Engineering College, Erode, India
3
Micromachining Research Centre (MMRC), Department of Mechanical Engineering, Sree Vidyanikethan Engineering College, Tirupati, India
replacement of fusion welding techniques by the FSW process to make use of its advantages. Like other welding processes, FSW also has a quite number of process parameters controlling the quality of the weld. Extensive works have been carried out in understanding the effect of process parameters on the welding of plat plates. The primary choice of factors for FSW process optimization includes tool design (pin profile and tool shoulder diameter), tool rota
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