Optimization and Characterization of Friction Welded Joint between A6061 Tube Plate and ASTM A106 Grade B Steel Tube Using Taguchi Method

Abstract

Friction welding of tube to tube plate has gained momentum due to its ability to join dissimilar metals, particularly those that are difficult to weld using traditional welding techniques. This paper aims to explore the influence of major parameters like rotational speed of the tool, shoulder diameter, and feed rate on mechanical properties such as pull strength and microstructural features of A6061 aluminum alloy and ASTM A106 Grade B steel in which welds joined them. An optimal selection of parameters was obtained through Taguchi L9 orthogonal array to achieve maximum pull strength. Results indicated that 1400 rpm for the tool rotational speed with a shoulder diameter of 40mm and a feed rate of 1.2 mm/min gave rise to solid connections. At the interface between welds, SEM studies demonstrated refined grain structure without any intermetallic compounds indicating good bonding between two materials. The XRD analysis showed no formation of intermetallic phases as evidenced by uniform distribution of elements across the interface region confirmed by EDS results. These findings imply that the chosen process variables effectively increase joint strength and ensure a strong weld is formed in FWTPET processes, which could lead to improved industrial applications where high-performance joints for dissimilar metals are needed.