Present study is focused on investigating the effect of various friction stir welding (FSW) process variables on AA6061/Rutile composites welding quality. FSWof composites was performed considering tool geometry (Tg), welding speed (Ws) and rotational speed (Ns) as ideal parameters for multi-response optimization. Experiments were designed based on the L9 orthogonal array. Analysis of variance (ANOVA) was utilized to evaluate the effects of these welding process variables on output responses namely hardness and ultimate tensile strength (UTS). Main effects plots were drawn to found out the optimal levels of these process parameters. Multi-response optimization of the welding process has been performed using Taguchi's grey relational analysis (TGRA). Analysis revealed that welding speed of 90mmmin-1, a tool with a square pin, and rotational speed of 1000 rpm produced an FSWjoint with excellent mechanical properties. Microstructure analysis revealed that refinement in the grain structure and redistribution of reinforced particles helped in improved joint strength.
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