Optimization of friction stir welding process parameter using taguchi method and response surface methodology

IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 02 Issue: 12 | Dec-2013, Available @ http://www.ijret.org 551
OPTIMIZATION OF FRICTION STIR WELDING PROCESS
PARAMETER USING TAGUCHI METHOD AND RESPONSE SURFACE
METHODOLOGY: A REVIEW
Satish P. Pawar1
, M. T. Shete2
1
M.Tech. student, Production Engineering, Govt. College of Engineering, Amravati, (M.S.) India.
2
Asst. Professor, Mechanical Engineering Department, Govt. College of Engineering, Amravati, (M.S.)India
satishpawar854@gmail.com, mtshete@yahoo.com
Abstract
Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment
friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter.
Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of
optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this
review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response
surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the
improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of
welded joint is tool rotational speed, welding speed, axial force and tool pin profile.
Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
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1. INTRODUCTION
Friction stir welding (FSW) is a solid state welding process
invented and patented by The Welding Institute (UK)
in1991[1]. It is one of the most significant developments in the
area of welding. FSW offers the potential for joints with high
fatigue strength; low preparation and little post weld dressing
and ability to join dissimilar material.[2] It involves joint
formation below the base material melting temperature.
Compared to many of the fusion welding processes that are
routinely used for joining structural alloys, friction stir
welding is an emerging solid state joining process in which the
material that is being welded does not melt and recast.
Avoiding melting prevents many of the metallurgical
problems that occur with conventional fusion welding, such as
distortion, shrinkage, porosity and splatter.[4].
1.1 Process
A non-consumable rotating tool with designed pin and
shoulder is inserted into the edges of the plates to join. The pin
traverses along the line of joint and the shoulder touches the
plates. Due to friction, the tool heats the work piece and
moves the material from a side to the other. Material plastic
deformation also increases the overall heat generated during
the pin and the combination of the pin rotation and translation
results in producing a welded joint in solid state.[3] Good
quality of welded joint between dissimilar materials is a very
useful for many emerging application including the ship
building, aerospace, transportation, power generation,
chemical nuclear industries.[2]
Fig-1. Illustration of Friction Stir Welding.
1.2 Optimization of Welding Parameter
The quality of a weld joint is directly influenced by the
welding input parameters during the welding process;
therefore input parameters plays a major role in deciding
quality of welded joint[8]. Various industries of welding
follow the conventional experimental procedure i.e. varying
one parameter at a time while keeping the other parameter

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constant. This conventional parametric design of the
experimental approach is time consuming and requires
excessive resources[12]. To solve this problem there are
different methods of achieving the desired output variables by
developing new models. In this review two methods of
optimization are studied i.e. Taguchi Method and Response
surface methodology[9]
Taguchi technique has been used widely for product or
process on determining parameters and their performance
measure with minimum variation. It is an efficient problem
solving tool which can improve the performance of the
product, process, design and system with a significant slash in
experimental time and cost[13].
Response Surface Methodology (RSM) is a collection of
mathematical and statistical techniques useful for the
modeling and analysis of problems in which a response of
interest is influenced by several variables and the objective is
to optimize this response[20]. The RSM is important in
designing, formulating, developing, and analyzing new
scientific studies and products. It is also efficient in the
improvement of existing studies and products. RSM will be
used to reduce the number of experiments, in addition to build
a numerical relation between the quality of welding and the
welding parameters.[23]
2. OPTIMIZATION MODELS OF FSW BY
TAGUCHI
The optimization models for FSW are develop by considering
a set of parameters in most cases tool rotational speed,
welding speed and axial force. The use of numerical
techniques that are specifically develop to reduce the cost of
expensive computer simulation are also available. These
include Space and Manifold technique , Genetic Algorithm
(GA), Stepecent Descent optimization and taguchi method.
Mohamadreza Nourani et al reviewed this technique.[29]In
this review study Taguchi optimization technique is focused
for review on optimization model. M Jayaram et al[11] they
optimize the FSW of cast aluminium alloy process parameter
such as Tool rotation speed, Welding speed and axial force
and evaluate. Optimum welding condition for maximizing
tensile strength is determined. In this study they found that the
Tool rotation speed is most Dominant parameter for tensile
strength followed by welding speed. Axial force shows
minimal effect on tensile strength compared to other
parameter. A maximum tensile strength (147 Mpa) exhibited
with optimal process parameters tool rotation speed 1200 rpm,
welding speed 40 mm/min and axial force 4 KN. The same
parameters studied by A.K.Laxminarayan et al[12] in friction
stir welding of RDE-40 Aluminium alloy of 6mm thickness
plate by butt joint .They also found that Tool rotational speed
has more contribution as compared to other parameters i.e.41
%and traverse speed -33%,axial force-21% and the value of
this optimum parameters for RDE 40 Al alloy is 400rpm,
45mm/min and 6 KN respectively.P. Murali et al [15] join the
5mm thickness dissimilar AA2024-T6 and AA6351-T6 Al
alloy by FSW and study the same parameters. Their results
obtain are 1200 rpm (67.31%), 1.2 mm/s (13.7%) and 7000 N
(14.5%) respectively.
The following researcher study some different parameters in
same type of welding with different material M Koilraj et
al[10] join the dissimilar Al-Cu alloy AA2219-T87 and
AA5083-H321 of 6mm thickness. The parameters taken are
Tool rotation speed, Transeverse speed and D/d ratio .
Cyllindrical threded pin profile found best among other tool
profile and contribute 60% to the overall contribution the
results obtain are 1200 rpm,15mm/min and D/d is 3
respectively. C Vidal et al [19] optimize the the friction stir
welding parameter to improve the Tensile strength and
bending toughness of AA2024-T351 alloy. The parameters
considered was vertical downward force, traverse speed and
pin length. They improve the Tensile strength and bending
toughness by 2.8 % and 10% by optimization.
High Density Polyethlene is one of the important material in
the class of thermoplastic material. It is replaced by
conventional material to reduce the weight of component.
Therefore joining of HDPE by FSW is also increasing demand
some researcher study the optimization of process parameters
in FSW of HDPE.
Mohammad Ali Rezgui et al [6] optimize the friction stir
welding process parameter of High Density Polyethylene 15
mm sheets by linear welding. They investigate the effects of
rotation speed, feed speed and tool plunge surface on
longitudinal flow stress. They optimize the parameter Tool
rotation speed, feed speed and tool plunged surface. Yahya
Bozkurt [18] joined 4 mm HDPE sheets and study the
parameters Tool rotation speed, Tool traverse speed and Tilt
angle and results obtained are 3000 rpm, 115 mm/min and 3°
respectively.
In This section optimization of Friction Stir Spot welding is
carried to optimize the parameters for Lap joint welding.
Mustafa K Bilici et al [9] optimize the parameters of 4mm
thick polypropylene. They study effect of process parameters
Tool rotational speed , Plunge depth and dwell time on weld
strength and optimize to obtain maximum strength. The
optimize parameters are tool rotational speed 900 rpm, plunge
depth 5.7 mm and dwell time 100 sec. Mohammad Hasan
hojaeefard et al [13] investigate the effect of tool rotational
speed, tool tilt angle and traverse speed in FSW of Aluminium
to Brass 2.5 mm sheets. The results obtained are 1120 rpm 1.5
° and 6.5 mm/min respectively they found that rotational
speed plays vital role and contributes 40% in overall
contribution. Yahya Bozkurt et al [16]join the 1.6 mm
AA2024-T3 and 1.5 mm AA5754-H22 aluminium alloys. Two
cases are studied in first case one plate took over another and
in second case vice versa. They conclude that the

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improvement in the LSFL from the initial welding parameter
to the optimal welding parameter was obtained for case 1
about 47% from 3.55 to 5.28 KN and only 1.1% for case 2
from 5.29 to 5.64 KN. In this Leonardo C.C. et al [17] replace
the parameter Tilt angle by dwell time and optimize them in
FSW of AZ31 Mg alloy 2 mm thickness Tool plunge depth
has the greatest influence on shear strength of joint and around
60% contribution. The optimize parameters are rotational
speed 2500 rpm, tool plunge depth 3mm and dwell time 1.5
sec.
3. PREDICTION MODELS OF FSW BY
RESPONSE SURFACE METHODOLOGY
The Mathematical models developed to predict the output
response and establish the relationship between input
parameter and output response by optimization. The various
methodology i.e. Response Surface Methodology and
Artificial Neural Network for developing mathematical
models are used in which Response Surface Methodology is
reviewed in this study. It has been proved by several
researchers that efficient use of statistical design of
experimental techniques allows development of an empirical
methodology to incorporate a scientific approach in the fusion
welding procedure.[25] V. Balasubramanian et al [20]
developed the empirical relationship to predict the tensile
strength of friction stir welded AA2219 Aluminium alloy of
6mm thickness joints by incorporating welding parameters and
tool profiles. Mathematical model predict that the joint
fabricated using square pin profile tool with rotational speed
1600 rpm, welding speed 0.75 mm/sec and axial force 12 KN
exhibited superior tensile properties. R.Palanivel et al [21]
joined 6 mm thickness AA6315 aluminium aaloy by butt joint.
They conclude that increase in tool rotational speed , welding
speed and axial force increase the ultimate tensile strength and
yield strength it reaches maximum and then decreases.But in
AA6061-T6 and AA7075-T6 al alloy ultimate tensile strength
increases with only increase in tool rotational speed and
welding speed upto and decreases with increases in axial
force.G.Elathrasan[22]. A.K.Laxminarayan et al [25] and V
Balasubramanian et al [26] develop mathematical model on
same parameters in FSW of AA7039 Al alloy 6 mm thickness
and RDE 40 Al alloy. Rotational speed has greater influence
on tensile strength. maximum tensile strength of 319 Mpa is
exhibited with optimized parameter of 1460 rpm rotational
speed, 40 mm/min welding speed and 6.5 KN axial force.
With above parameters R.Palanivel et al [24] study the Tool
pin profile in FSW of AL alloy dissimilar AA6351-T6 and
AA5083-T6 6mm butt joint. the joints fabricated straight
square pin profiled tool with a rotational speed of 950 rpm,
welding speed of 63 mm/min and axial force of 14.72 kN
exhibited superior tensile quality. Jawdat A. Al-Jarah et al
[23] vary the thickness of the welding plate of aluminium
alloy from 4 to 8 thickness and develop empirical relationship
to predict the yield strength and hardness of joint. Tool
rotational speed, welding speed and tool shoulder diameter are
also taken into consideration. I Dinaharan et al [27] identify a
set of friction stir welding parameters to join aluminium
matrix composites which will give higher tensile strength,
ductility and wear resistance. The process parameters
considered were tool rotational speed, welding speed, axial
force and weight percentage of ZrB2. Mathematical models
were developed and optimize using generalized reduced
gradient method. The results obtained are tool rotational speed
1132 rpm, welding speed 51 mm/min, axial force 5.8 kN and
ZrB2 is 10 wt. % . The predicted parameters are UTS 226
Mpa, E 0.76 % and W 286.15*10-5
mm³/m. The optimize
process parameters can be used to automate the FSW process
to achieve desirable joint properties.
CONCLUSIONS
 From the above review it is conclude that Tool rotational
speed, Welding speed, Axial force and Tool pin profile
are most significant parameters. Optimizing these
parameters gives better quality of welded joint.
 In this review two methods for optimization are studied
i.e. Taguchi method and Response surface methodology
 Taguchi method gives the optimize parameters for
getting desire output while Response surface
methodology establish empirical relationship between
welding input input parameter and output response and
develop the mathematical model to predict the output
response.
 In this review study mostly the 6 mm thickness sheets are
taken for and most of the researchers prefer the butt joint
for linear welding.
 The predicted results by optimization is very closure to
actual experimental value
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