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<p>Friction stir welding a solid state joining process solution for aluminium alloys, conquering the drawbacks of traditional fusion welding such as porosity, solidification cracking, and weak joints. This study presents an experimental analysis of FSW joints in AA3103 aluminium alloy using three tool pin profiles: circular, triangular, and square. A Taguchi L9 orthogonal array was used to improve process parameters such shoulder to pin diameter ratio (D/d), welding speed (WS), and tool rotating speed (RPM). A Universal Testing Machine (UTM) was used to assess mechanical qualities like ultimate tensile strength (UTS), yield strength (YS), and percentage elongation (%E). These results followed by association with microstructural features and surface roughness. Statistical tools including ANOVA and regression were used to identify significant factors and predict performance. Experimental investigation revealed that the D/d ratio significantly affects the UTS and YS, with the circular pin profile yielding the most consistent and predictable outcomes. The square pin showed the highest UTS, while the triangular pin exhibited superior elongation. Surface roughness analysis confirmed smoother welds at lower RPM and optimal WS, particularly with circular and square pins. Microstructure analysis revealed finer, equiaxed grains in the nugget zone for the circular pin, correlating with improved mechanical properties. Overall, the circular pin profile is recommended for achieving high-quality, balanced, and repeatable FSW joints in AA3103.</p>

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Experimental Investigation and Analysis of Friction Stir Welded Aluminium AA3103 Joint by Taguchi Approach

  • 期刊论文

  • 发表日期：

    2026年1月2日

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  • Shailesh S. Parkhe,
  • Rupesh J. Patil

摘要

Friction stir welding a solid state joining process solution for aluminium alloys, conquering the drawbacks of traditional fusion welding such as porosity, solidification cracking, and weak joints. This study presents an experimental analysis of FSW joints in AA3103 aluminium alloy using three tool pin profiles: circular, triangular, and square. A Taguchi L9 orthogonal array was used to improve process parameters such shoulder to pin diameter ratio (D/d), welding speed (WS), and tool rotating speed (RPM). A Universal Testing Machine (UTM) was used to assess mechanical qualities like ultimate tensile strength (UTS), yield strength (YS), and percentage elongation (%E). These results followed by association with microstructural features and surface roughness. Statistical tools including ANOVA and regression were used to identify significant factors and predict performance. Experimental investigation revealed that the D/d ratio significantly affects the UTS and YS, with the circular pin profile yielding the most consistent and predictable outcomes. The square pin showed the highest UTS, while the triangular pin exhibited superior elongation. Surface roughness analysis confirmed smoother welds at lower RPM and optimal WS, particularly with circular and square pins. Microstructure analysis revealed finer, equiaxed grains in the nugget zone for the circular pin, correlating with improved mechanical properties. Overall, the circular pin profile is recommended for achieving high-quality, balanced, and repeatable FSW joints in AA3103.