Optimisation and Process Investigation of Friction Stir Welded Aa6351 Aluminium Alloy Using Taguchi L27 Orthogonal Array

Abstract

The friction stir welding (FSW) process has gained significant attention for joining aluminium alloys due to its ability to produce defect-free welds with superior mechanical properties. This study focuses on optimizing and enhancing the friction stir welding parameters of AA6351 aluminium alloy using the Taguchi L27 orthogonal array methodology. The key process parameters considered include rotational speed, welding speed, and axial force.

An experimental design based on the Taguchi L27 orthogonal array was employed to systematically investigate the effects of these parameters on the tensile strength, hardness, and microstructure of the welded joints. Analysis of Variance (ANOVA) was used to identify the significance of each parameter and their interactions on the welding quality.

The results demonstrated that the rotational speed and welding speed significantly influence the tensile strength and hardness of the welds, while the axial force primarily affects the micro structural characteristics. Optimal parameter settings were identified, which led to enhanced mechanical properties and a finer, more homogeneous microstructure in the welded joints. This study provides a robust framework for optimizing FSW parameters using the Taguchi method, contributing to the improvement of weld quality in AA6351 aluminium alloys. The findings are expected to benefit industries where lightweight and high-strength aluminium structures are critical, such as aerospace and automotive sectors.