Experimental investigation and parametric optimization of FSW of mineral-reinforced AA6061 matrix composite

Abstract In this work, rutile reinforced AA 6061 matrix composites were joined using friction stir welding and the process variables were optimized using Taguchi L27 orthogonal design of experiments. The rotational speed, axial force and tool tilt angle were the parameters taken into consideration. The optimum process variables were determined with reference to tensile strength, impact strength and hardness of the joint. The predicted optimal value of output responses was confirmed by conducting the confirmation run using optimum parameters. The optimal process variables combination values that resulted in improved mechanical properties were observed at a tool rotational speed of 1400 rpm, a tool tilt angle of 2 degree, and an axial force of 3KN. Scanning electron microscopy (SEM) analysis were used to probe the microstructures.