Parametric optimization of friction stir welding process parameters of dissimilar welded joints using grey relational analysis and desirability function approach

Abstract

Purpose The main purpose of the present work is to study the multi response optimization of dissimilar friction stir welding (FSW) process parameters using Taguchi-based grey relational analysis and desirability function approach (DFA). Design/methodology/approach The welded sheets were fabricated as per Taguchi orthogonal array design. The effects of tool rotational speed, transverse speed and tool tilt angle process parameters on ultimate tensile strength and hardness were analyzed using grey relational analysis, and DFA and optimum parameters combination was determined. Findings The tensile strength and hardness values were evaluated from the welded joints. The optimum values of process parameters were estimated through grey relational analysis and DFA methods. Similar kind of optimum levels of process parameters were obtained through two optimization approaches as tool rotational speed of 1150 rpm, transverse speed of 24 mm/min and tool tilt angle of 2° are the best process parameters combination for maximizing both the tensile strength and hardness. Through these studies, it was confirmed that grey relational analysis and DFA methods can be used to find the multi response optimum values of FSW process parameters. Research limitations/implications In the present study, the FSW is performed with L9 orthogonal array design with three process parameters such as tool rotational speed, transverse speed and tilt angle and three levels. Practical implications Aluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. Originality/value Very limited work had been carried out on multi objective optimization techniques such as grey relational analysis and DFA on friction stir welded joints made with dissimilar aluminium alloys sheets.