Computational Investigation of Friction Stir Processing of Ti-6Al-4V Alloy for Biomedical Applications Using FEM and Taguchi Design

Friction stir processing (FSP) is an advanced solid-state surface modification technique for biomedical titanium alloys. This study presents a computational investigation of FSP applied to Ti-6Al-4V alloy through three-dimensional finite element modeling and Taguchi-based statistical optimization. A Taguchi L9 orthogonal array evaluated rotational speed (400–1000 rpm), traverse speed (50–100 mm/min), shoulder diameter (6–18 mm), and pin diameter (2–6 mm), reducing the required simulations from 81 (full factorial) to nine (88.9% reduction). A calibrated friction model (μ = 0.35/0.25/0.20 for 400/800/1000 rpm, F = 6000 N) yielded maximum temperatures of 870–1384 °C; all predicted temperatures remained below the melting point of Ti-6Al-4V (1660 °C). These values are consistent with experimentally reported ranges for FSW/FSP of Ti-6Al-4V. Traverse speed is the dominant parameter (ANOVA contribution: 63.1%, F = 10.44), followed by rotational speed (26.7%) and shoulder diameter (4.1%). Simulation 3 (400 rpm, 100 mm/min, Ds = 18 mm, T_max = 870 °C) appears to be the most promising thermal condition for preserving the fine-grained α + β microstructure, as it remains below the β-transus temperature (980 °C) throughout the processed zone.