Integrated Taguchi cum grey relational experimental analysis technique (GREAT) for optimization and material characterization of FSP surface composites on AA6061 aluminium alloys

This work focuses on the optimization of process parameters for friction stir processed (FSP) AA 6061 for superior mechanical properties. The distinctive work is to integrate the Taguchi Method with the Grey Relational Experimental Analysis Technique (GREAT) for a hybrid portfolio. Eight experimental investigations were carried out with varying process parameters of two levels of tool speed (25 and 28 mm/s), processing speed (1000 and 1500 rpm) and pin profiles (cylinder and square) with reinforcements such as Silicon carbide (SiC), Titanium Carbide (TiC), Titanium DiBromide (TiB2) and Zirconium DiBromide (ZrB2) to uncover the influence that it holds to the process. Surface composites quality of all the samples was evaluated for tensile strength. After a single pass of FSP. TiC reinforcement showed a promising optimized welding quality at 1500 rpm, 25 mm/s with a square pin profile by GREAT. when TiC reinforcement was used along with the rotational speed of 1500 RPM, the processing speed of 25 mm/s with a square pin profile as a process parameter and significant improvement of 37.85% and 46.6% for tensile strength and yield strength respectively due to the grain refinement of added reinforcement particle dispersoids, processed AA6061 composites showed significant improvement in terms of material property. (C) 2019 Elsevier Ltd. All rights reserved.