Taguchi optimization of friction stir process parameters for enhancing joint strength of AA8011 reinforced with SiC nano particles

In the present study, an attempt is made to analyze the characteristics of friction stir Processing of AA8011 with Reinforcement of Nano Silica Carbide. AA8011, an aluminum alloy, belongs to the 8xxx class. Application of this material mainly for producing aluminum foil due to its exceptional formability, resistance to corrosion and superior thermal conductivity which makes it suitable for use in heat transfer applications also. In addition, this alloy is useful for producing reflecting insulating materials due to its high reflectivity. Whereas Carborundum, another name for silicon carbide (SiC), is a hard chemical compound made of silicon and carbon. In the present study, a known quantity of powder is poured into the micro holes which are made using micro drill EDM on Aluminum plate AA8011. To evaluate the properties of SiC Reinforced AA8011 FSP is chosen because it creates frictional heat in the adjacent surfaces using a non-consumable electrode. The Taguchi optimization of FSP of AA8011 with Nano SiC reinforcement by varying input parameters, including Tool Rotational Speed (TRS), Feed Rate (FR) and Tool Tilt Angle (TTA) was performed. A total 9 no of experiments were conducted and output response Such as Yield Strength (YS), Ultimate Tensile Strength (UTS), %Elongation (%EL) and Hardness were evaluated. Optimum condition for YS and UTS obtained at combination of TRS at level 3 (1120 rpm), FR at level 2 (40 mm/min) and TTA at level 2 (1°). Optimum conditions for %EL and hardness obtained at the combination TRS at level 1 (560 rpm), FR at level 3 (50 mm\min) and TTA at level 1 (0°). Regression analysis was used to examine the joint quality of welded specimens in terms of YS, UTS, %El and Hardness. The fracture surface of the tensile specimen was examined through Scanning Electron Microscope (SEM) Analysis which revealed a ductile facture morphology. From the ANOVA analysis the most influencing parameter for YS is interaction of TRS*FR, for UTS is TRS, for %El is FR and for Hardness is interaction of TTA*TTA.