Process parameters optimization on FSW of Polycarbonate and AA6061

A drastic use of thermoplastics is observed in versatile industries which includes aerospace and automotive industries where thermoplastics and metal combinations are used. Differences in physical and mechanical traits of chosen materials FSW (Friction Stir Welding) is mainly utilized in welding metal to thermoplastic. FSW avoids significant changes in microstructure and also solve the conventional problems in fusion welding. Higher production rate would be achieved if parameters are selected optimally during Friction stir welding by implementing Taguchi method and analysis of variance (ANOVA analysis). To detect the effect of considered parameters like welding speed, plunge depth, rotational speed and joint strength post FSW of Polycarbonate and AA6061. An orthogonal array of size L4 has been selected to know the optimal levels of FSW of Polycarbonate and AA6061. After analysis from the ANOVA technique it has been found that the speed of rotation is the most significant factor and welding speed is least significant factor effecting the strength of joint post FSW of Polycarbonate and AA6061. The optimum conditions to achieve the tensile strength maximum value of 10.33 MPa are 1400 rpm, 10 mm/min and 1.2 mm. (C) 2019 Elsevier Ltd. All rights reserved.