Optimization of FSW process parameters for welding dissimilar 6061 and 7075 Al alloys using Taguchi design approach

Friction stir welding (FSW) produce a strong metallurgical joint with the application of severe deformations and frictional heating in the metals and alloys by using a non-consumable rotating tool consisting of pin and tool shoulder. During welding, the plastic deformations of base metals vary for the varying mechanical properties such as tensile strength (TS), impact strength (IS), and hardness (HV) which in turn varies the welding conditions and parameters. Therefore, selection of optimal weld parameters plays an important role in enhancing the quality of weld joint. In this article, friction stir butt welds made of 6061 and 7075 Al alloys are performed with various welding parameters such as rotational speed of tool, angle of tilt, and axial force using tool has taper pin profile. Experiments are carried out on twenty-seven joints that are made on 6061 and 7075 Al Alloy plates of 6.50 mm thick of same nature and tested for its tensile, impact and HV properties.