Grey-Taguchi Approach for Optimizing FSW Parameters in Joining AA6262 and AA5083 Alloys

T his study concentrates on the friction stir welding (FSW) joining of dissimilar AA6262 and AA5083 plates. Four input parameters, namely tool rotational speed (TRS), welding speed (WSP), tool tilt angle (TTA), and pin depth (PDP) are chosen to analyze the output responses of tensile strength (UTS), hardness (HBN), and wear rate (WTR) in welding. The primary objective is to optimize the variables of the FSW process for AA6262 and AA5083 alloys using a combination of Taguchi and Grey Relational Analysis (GRA) methods, while also comprehending the correlations among process variables through the application of these two methods. Utilizing the Taguchi approach, L27 orthogonal array is constructed for conducting FSW experiments. After this, the multi-objective optimization challenge is streamlined into a single-objective optimization task by leveraging the grey relational degree. The significance and impact of the distinct variables are elucidated through the application of Analysis of Variance (ANOVA). Confirmation tests and predictive analysis are performed to validate the optimal variables, which are then compared against the acquired outcomes. The results highlight the welding speed as the paramount parameter, exerting substantial influence over the output responses of the welds in contrast to the other variables under examination. The application of the Grey-Taguchi methodology yields enhancements in Tensile Strength (245.23 MPa) and Hardness (99.2 Hv), while concurrently decreasing the Wear Rate (0.00456 m3/Nm). Furthermore, the Grey Relational Grade exhibits an advancement of 0.1312. These findings collectively signify an increased operational efficiency in the welding process, particularly for dissimilar alloys.