Optimization of friction welding parameters for AA6061-T6/AA2024-T6 joints using Taguchi-Simulated annealing (TSA) algorithm

Friction welding is an economical solid state joining process which has gained industrial acceptance for producing dissimilar joints with light weight applications. In this work continuous drive friction welding was employed to produce AA6061-T6/AA2024-T6 joints. The process parameters which influence the quality characteristics of the joint like the frictional pressure, upset pressure, rotational speed and burn off length were varied in three levels and the experimental trials were designed by Taguchi's L-9 orthogonal array. Yield strength, ultimate strength and micro-hardness in the weld area were observed as the responses for the various trials. Weighted S/N (WSN) ratio was calculated for each trial by utilizing the weights generated by simulated annealing (SA) algorithm. The optimal levels were sorted out by taking the WSN ratio as a measure of performance and a confirmation experiment was conducted for validation. The results of ANOVA had revealed the significant contribution of upset pressure in affecting the quality characteristics.