The quest of automobile industries for weight reduction and enhancement of the mechanical strength of components has been a major incentive for new manufacturing technologies such as thixocasting. It is therefore important that the welded joints of such components exhibit adequate strength and formability. The present investigation is on optimization of process parameters to achieve better weld quality obtained in friction-welded joints of thixocast A356 aluminum alloy. The optimum combination of welding parameters is obtained by using the analysis of the signal-to-noise (S/N) ratio based on the Taguchi method. Joint strength higher than the parent material strength is achieved with an optimum set of friction-welding parameters. In addition, residual stress analysis is carried out both experimentally and numerically. Comparisons between the experimental and numerical residual stresses are in good agreement with each other. The residual stress obtained is of low magnitude and compressive in nature.

中文翻译：

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触变铸造A356铝合金摩擦焊最佳工艺参数及残余应力的确定

汽车工业对减轻重量和提高部件机械强度的追求一直是触变铸造等新制造技术的主要动力。因此，此类部件的焊接接头必须具有足够的强度和可成形性，这一点很重要。目前的研究是优化工艺参数，以在触变铸造 A356 铝合金的摩擦焊接接头中获得更好的焊缝质量。通过基于田口方法的信噪比（S/N）分析，获得焊接参数的最佳组合。连接强度高于母材强度是通过一组最佳摩擦焊接参数实现的。此外，残余应力分析是通过实验和数值进行的。实验和数值残余应力之间的比较彼此非常吻合。获得的残余应力是低量级和压缩性的。