Present study is focused on investigating the effect of various friction stir welding (FSW) process variables on AA6061/Rutile composites welding quality. FSW of 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 90 mm min⁻¹, a tool with a square pin, and rotational speed of 1000 rpm produced an FSW joint with excellent mechanical properties. Microstructure analysis revealed that refinement in the grain structure and redistribution of reinforced particles helped in improved joint strength.

目前的研究重点是研究各种搅拌摩擦焊 (FSW) 工艺变量对 AA6061/金红石复合材料焊接质量的影响。复合材料的 FSW 考虑工具几何形状 (Tg)、焊接速度 (Ws) 和转速 (Ns) 作为多响应优化的理想参数。实验是基于L9正交阵列设计的。方差分析 (ANOVA) 用于评估这些焊接工艺变量对输出响应的影响，即硬度和极限抗拉强度 (UTS)。绘制主效应图以找出这些工艺参数的最佳水平。使用田口的灰色关联分析 (TGRA) 对焊接过程进行了多响应优化。分析表明，焊接速度为 90 mm min ^-1，带有方形销的工具和 1000 rpm 的转速产生了具有优异机械性能的 FSW 接头。微观结构分析表明，晶粒结构的细化和增强颗粒的重新分布有助于提高接头强度。