Friction Stir Welding Process Optimization on 4 Tool pin Geometries with Process Parameters and Shoulder Concave Angle in 6005A-T6 Aluminium Alloy Joining

Abstract

FSW is a welding process which done by movement of tool against the workpiece. Tool is an important part in FSW process because tool generates most of the heat in the FSW process, so the tool material and geometry are important because they receive high stress and temperature. This research was conducted to decide the best pin geometry for tool from the 4-pin geometry that has been decided, which is straight cylindrical, tapered cylindrical, hexagonal, and tapered square. The optimization process is done with Taguchi method using 4 factors where each factor has 4 levels, factors that used in this research are tool rotation speed, welding speed, tool shoulder angle, and tool tilt angle with the respond is temperature at welding joint. The optimization process will be done in all of the pin geometries that has been decided and the best pin geometry out of 4 geometries will be chosen. The best pin out of 4 geometries is the hexagonal pin with the optimized parameters are the rotational speed of 1208 rpm, welding speed of 65 mm/min, tilt angle of 2.5° and concave angle of 2° with max. temperature of 322.48°C. The significant factor obtained was the tool rotational speed and concave angle with significance level of 95%.