optimization of friction stir welding parameters with taguchi method for maximum electrical conductivity in al-1080 welded sections

This paper attempts to optimize welding parameters. the strength and quality of fswed (friction stir welding) sections are affected by materials transfer, work hardening, and transformations. these properties depend strongly on materials transfer, which is under the control of welding parameters. the soundness of friction stir welded sections is usually studied by non destructive test (ndt) techniques. however, it could be characterized by physical properties such as electrical conductivity. the higher electrical conductivity implies less defects and higher welding quality. for this purpose, the taguchi l9 orthogonal design of experiment was used to optimize the welding parameters. the optimum process parameters and their effectiveness in the electrical conductivity of welded sections were analyzed by signal-to-noise (s=n) ratio and analysis of variance (anova) tests. the results indicated that the tilt angle and tool shape were the most influential parameters to catch the maximum conductivity in welded joints. the optimum tool shape and tilt angle were cylindrical and 3° , respectively. the optimum conditions for welding and rotational speeds were characterized by 100 mm/min and 900 rpm in the stir zone, 250 mm/min and 900 rpm in advancing side (as), and 100 mm/min and 450 rpm in retreating side (rs), respectively.