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<p>Friction stir welding (FSW) is one of the most effective solid state joining techniques particularly of high strength aluminum alloys (e.g., AA7075) which are commonly utilized in aerospace and automotive applications for its excellent strength-to-weight ratios. Nevertheless, the issues of surface integrity and tribological properties limit its more extensive use. This article presents an investigation of the effects of the most important FSW parameters, namely the tool pin profile (TP), tool tilt angle (TA), the traverse speed (TTS), and rotational speed (RPM) on the two most significant output responses, i.e., surface roughness (Ra) and wear rate. In the L18 orthogonal array of Taguchi experimental design, and the Grey Relational Analysis (GRA) was used for optimization, both the responses were considered to minimize concurrently. The analysis of variance (ANOVA) revealed that traverse speed was the most influential factor, accounting for 43.80% wear rate, 42.71% surface roughness and 40.69% overall grey relational grade (GRG), while the rotational speed followed. The best parameter combination, TP2, TTS 23&#xa0;mm/min, TA 2°, and RPM 1100, led to the minimum wear rate at 291.27&#xa0;mm³/m, the least surface roughness at 2.78&#xa0;μm as well as the highest gray relational grade at 0.96. Regression models for response prediction had high prediction accuracy (R² &gt; 90%) and confirmation tests showed that optimization was robust with prediction errors being ± 3%. Polymer surfaces were found to exhibit refined equiaxed grains and intermediate smoothness at the optimal conditions through scanning electron microscopy (SEM) investigation, and grooves, delamination, and debris at nonoptimal conditions. The results reveal that Taguchi–GRA is a robust tool for the optimization of the multi objective problem, which helps in improved productivity and weld quality in the AA7075 FSW applications.</p>

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Improving productivity and quality in FSW of AA7075 by optimising welding parameters for surface roughness and wear using Taguchi GRA

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年2月7日

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  • Aman Kumar,
  • Pardeep Gahlot,
  • Rakesh Kumar Phanden,
  • Ajay Kumar

摘要

Friction stir welding (FSW) is one of the most effective solid state joining techniques particularly of high strength aluminum alloys (e.g., AA7075) which are commonly utilized in aerospace and automotive applications for its excellent strength-to-weight ratios. Nevertheless, the issues of surface integrity and tribological properties limit its more extensive use. This article presents an investigation of the effects of the most important FSW parameters, namely the tool pin profile (TP), tool tilt angle (TA), the traverse speed (TTS), and rotational speed (RPM) on the two most significant output responses, i.e., surface roughness (Ra) and wear rate. In the L18 orthogonal array of Taguchi experimental design, and the Grey Relational Analysis (GRA) was used for optimization, both the responses were considered to minimize concurrently. The analysis of variance (ANOVA) revealed that traverse speed was the most influential factor, accounting for 43.80% wear rate, 42.71% surface roughness and 40.69% overall grey relational grade (GRG), while the rotational speed followed. The best parameter combination, TP2, TTS 23 mm/min, TA 2°, and RPM 1100, led to the minimum wear rate at 291.27 mm³/m, the least surface roughness at 2.78 μm as well as the highest gray relational grade at 0.96. Regression models for response prediction had high prediction accuracy (R² > 90%) and confirmation tests showed that optimization was robust with prediction errors being ± 3%. Polymer surfaces were found to exhibit refined equiaxed grains and intermediate smoothness at the optimal conditions through scanning electron microscopy (SEM) investigation, and grooves, delamination, and debris at nonoptimal conditions. The results reveal that Taguchi–GRA is a robust tool for the optimization of the multi objective problem, which helps in improved productivity and weld quality in the AA7075 FSW applications.