Application of Taguchi Method in the Optimization of Friction Stir Welding Parameters of an Aeronautic Aluminium Alloy

The Friction Stir Welding (FSW) process is still an innovative solid state mechanical processing technology enabling high quality joints in materials previously considered with low weldability such as most of the aeronautic aluminium alloys. The Taguchi method was used to find the optimal FSW parameters for improvement mechanical behaviour of AA2024-T351. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized. The parameters considered were vertical downward forging force, travel speed and pin length. An orthogonal array of L9 (34) was used; ANOVA analyses were carried out to identify the significant factors affecting tensile strength (GETS), bending toughness (GEB) and hardness field. An algebraic model for predicting the best mechanical performance was developed and the optimal FSW combination was determined using this model. The results obtained were validated by conducting confirmation experiments. Significant interest has been shown in the use of advanced welding techniques for aircraft structures, particularly given the design and manufacturing benefits they afford over established mechanical joining methods. Whilst a variety of welding methods have been identified for airframe structures, friction stir welding is an important candidate technique that is distinctive in being a low energy, solid-state process [1]. Although the friction stir welding joints have a better quality compared to the fusion techniques, there are still some defects that may arise and which are very sensitive to small variations in process parameters. Typical defects that may arise in FSW joints result from: imperfect stir of the materials during the processing, inadequate surface preparation, lack of penetration of the pin and non-uniform vertical forging forces along the material thickness. Some characteristic FSW defects are lack of penetration (typically addressed as kissing-bond), root flaw (concerning weak or intermittent linking), voids on the advancing side and second phased particles and oxides alignment under the shoulder [2]. Advanced aerospace aluminium alloys have been required to allow high fracture toughness, higher fatigue performance, high formability, and superplasticity to meet the needs for lower structural weight, higher damage tolerance and durability [3].