Utilizing Taguchi and ANOVA methods to investigate standard deviation of programmed torque for aluminum 6061-T6 friction stir welding with adaptive torque monitoring and control

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters Pub Date : 2025-09-01 DOI:10.1016/j.mfglet.2025.08.004

Austin Clark , Ihab Ragai

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Abstract

A Taguchi L₉ orthogonal array and Analysis of Variance (ANOVA) test for equal variance were used to determine variation in torque when adaptive torque monitoring and control is used in a Friction Stir Welding (FSW) application on AA6061-T6. Standard deviation was analyzed against the parameters of Programmed Torque (PT) and Feed Rate (FR). PT for the Z-axis motor determined the axial force at the tool during welding. PT values of 35, 40 and 45 Nm and FR of 100, 200 and 300 mm/min were studied in this paper. PT values of 35, 40 and 45 Nm correlated to 7.33, 8.38 and 9.43 kN axial force, respectively. It was found that the optimal parameter set with the lowest variation in torque through the entirety of the weld was conducted with a PT (45 Nm/9.43 kN) and an FR of 100 mm/min. These were the maximum and minimum values for PT and FR, respectively. Higher levels of torque variation occurred with higher FR and lower PT. This study offers insight into the effects process parameters have on torque variation when adaptive torque monitoring and control is used.

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采用田口法和方差分析方法研究6061-T6铝搅拌摩擦焊接程序转矩的标准差，并进行自适应转矩监测与控制

采用田口L9正交试验和方差分析（ANOVA）等方差检验来确定自适应扭矩监测和控制在AA6061-T6搅拌摩擦焊（FSW）应用中的扭矩变化。根据程序转矩（PT）和进给速率（FR）参数分析了标准偏差。z轴电机的PT决定了焊接过程中工具的轴向力。研究了PT值为35、40和45 Nm， FR为100、200和300 mm/min。PT值为35、40和45 Nm时，轴向力分别为7.33、8.38和9.43 kN。结果表明，在PT （45 Nm/9.43 kN）和FR为100 mm/min时，整个焊缝扭矩变化最小的最佳参数设置。这分别是PT和FR的最大值和最小值。高FR和低PT会导致更高的扭矩变化水平。该研究深入了解了在使用自适应扭矩监测和控制时，工艺参数对扭矩变化的影响。

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