Integrated MCDM based optimization and sensitivity analysis of process signals in friction stir spot welding of dissimilar al 6061 to polycarbonate Ajit K. Pattanaik, Tarakeswar Barik, Kamal Pal, Raj K. Bisoyi, Debadutta Mishra Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications, 2025 The present work addresses the feasibility of friction stir spot welding (FSSW) of metallic aluminum alloy ( Al6061) to thermoplastic polycarbonate ( PC ) sheets using a tapered pin tool incorporating real-time process monitoring with thrust-torque signals. Sensitivity analysis identified axial tool thrust during dwelling as the most superior indicator for joint integrity (≥ 40.1%) due to its role in enhancing interfacial mixing and bonding. The tool revolving speed primarily governs the process stability (≥ 30.9%) and thus predominantly enhances the weld strength (36.5 MPa) through controlled materials stirring. In contrast, dwell time governs the joint ductility (35.5%) by promoting adequate consolidation, while plunge depth dictates the weld hardness (43%) through prolonged deformation along dissimilar interface. An integrated multi-criteria decision-making (MCDM) analysis using ARAS, TOPSIS, and GRA provided consistent optimization trends with a strong rank correlation coefficient (> 0.9), confirming methodological reliability. The findings establish a quantitative framework for optimizing FSSW of dissimilar Al-PC , offering a validated approach for achieving improved mechanical behaviour through balanced process stability.
Weld quality monitoring in friction stir lap joining of dissimilar Al6061 to polycarbonate using thrust–torque-based process stability signatures Nisith Ku Goswami, Raj K Bisoyi, Kamal Pal Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2024 The joining of dissimilar aluminium-based alloys to thermoplastic polymers is highly challenging which indicates the necessity of friction welding procedures. The present work addresses the degrees of steadiness in welding thrust-torque to monitor the lap weld contour of aluminium alloy (Al6061) overlapped on polycarbonate sheet or vice versa using friction stir welding. The primary objective was to compare the monitoring capability of the weld non-uniformity by using raw signals and stability signature of welding thrust and stirring torque. Further, these stability indices were used for the prediction of weld mechanical behaviour using response surface methodology. The stability signatures were found to be a better indicator of weld profile unevenness than raw signals as it was an amplified version of the local deviations in welding thrust-torque. Improved strength efficiency up to 49% was noticed in PC-Al welds due to improved process stability at intermediate tool traverse (55 mm/min) and revolving speeds (1100 rpm). The stability in stirring torque was better indicator of weld quality features than tool thrust steadiness in Al-PC lap while it was reversed in PC-Al lap. Thus, the thrust force instability was mostly indicated the joint ductility while combined steadiness in thrust-torque were essential for the prediction of weld strength. The higher stability index in tool thrust (≥7.5) with ample torque steadiness (5–8) can upgrade the Al-PC weld strength (≥20 MPa), whereas intermediate thrust stability (6–6.5) with high stable torque (≥7) can uplift the joint strength (≥25 MPa) in PC-Al welds.
Sensor-based strategies for accurate prediction of drilled hole surface integrity of CFRP/Al7075 hybrid stack Tarakeswar Barik, Kamal Pal, Priyabrata Sahoo, Karali Patra Mechanics of Advanced Materials and Structures, 2024 The airplane structure is often made up using carbon fiber reinforced plastic (CFRP) stacking with a metallic sheet to improve excessive load carrying and shock-absorbing capability with reduced fuel economy. It is a challenging task to drill dissimilar CFRP-Al metallic stack because the hot continuous metallic chip mutilates the hole surface in addition to drilling-induced delamination. The present work addresses the parametric effect on delamination, roughness, and circularity error of the drilled hole along with chip morphology using different drill geometry on the fabricated CFRP [0°/-45°/90°/45°]2s stack over an aluminum 7075 sheet. A drill tool dynamometer was used to capture axial thrust with associated torque variations during drilling which were further used in process monitoring. The most critical unlike interface drilling has been scrutinized using instantaneous force-torque slopes along with scanning electron micrographs. The machining time loss during CFRP→Al interface drilling has also been processed. Finally, a comparative assessment has been made on the predictability of hole quality features among various sensor-based strategies using response surface methodology. The drilled-hole surface quality was significantly improved at high spindle speed (2250 rpm), and low feed rate (0.025 mm/rev) using a low drill point angle (110°). The thrust force was found to be a prime indicator of drilled hole integrity than torque whereas peak torque and its slope in the initial stages of the drilling cycle strongly correlated with surface delamination. The top surface delamination was somewhat severe (≥ 1.6) at high drill thrust (≥ 40 N) with high torque (≥ 0.45 Nm).
Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures Ajit K Pattanaik, Lalita P Nayak, Raj K Bisoyi, Kamal Pal, Debadatta Mishra Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science, 2024 Friction stir processing procedures are often found to be an alternative choice for the joining of thermoplastic polymers without melting the base materials. In recent years, dissimilar metallic to thermoplastic assemblies are highly used in aerospace and automotive industries as mechanical fastener or fusion welding techniques are rather inadequate for extreme discrepancy in thermal properties. The present work addresses the feasibility of friction stirred spot welding for non-ferrous aluminium (Al 6061) to polycarbonate using taper cylindrical tool of hardened H13 steel along with machine integrated axial thrust and stirring torque signals. The real-time positional and axial velocity of the rotating tool has been acquired to distinguish between plunging and dwelling stage. The process stability that is, the deviation of thrust-torque in respective phases was processed. The interaction of plunge depth and dwell time on tool pin assisted keyhole with associated material expulsion for different tool revolving speed was established. The weld mechanical behaviour has been scanned using load versus elongation diagram with associated weld pair interface. Lastly, sensors’ based process monitoring extended to weld quality prediction have been made using various significant features of thrust-torque-velocity based approaches. The tool spinning speed followed by dwell time was found to be important on weld quality index. The joint efficiency was significantly upgraded (more than 60%) at intermediate dwell time (40 s) with low tool plunging (0.3 mm) or reversed parametric setting at high tool revolving speed (2500 rpm) due to substantial reduction in axial thrust with higher stirring torque. The local deviation in thrust-torque during plunging was equally responsible with global mean thrust-torque in dwelling to dictate the joint strength and the weld ductility. The material stirring torque was better indicator of weld shear strength while pin assisted slot size highly correlated with tool thrust though tool plunging speed was highly crucial.
Optimization of process variables in drilling of carbon fiber reinforced plastics using various multi criteria decision making approaches T. Barik, K. Pal Materialwissenschaft Und Werkstofftechnik, 2023 Carbon fiber‐reinforced polymers are one of the lightweight materials used in structural design due to their exceptional mechanical performances. The drilling operation is indispensable as it facilitates the assembling of various manufactured components. However, drilling of fibrous laminates is deemed difficult in comparison to the traditional metals because of the anisotropic and non‐homogeneous nature. The present work addresses the parametric effect on the drilled hole delamination and further reduces it with an optimal combination of parameters for multi‐objectives using different multi‐criterion decision‐making techniques. Initially, the response surface‐based regression model of delamination as a function of three static inputs has been developed, further revised with induced thrust as well as mean torque for the improvisation of the prediction capability. Finally, for the overall improvement, a decision‐making model has been used that includes grey relation analysis, technique for order performance by similarity to ideal solution, and VIšekriterijumsko Kompromisno Rangiranje method. The delamination was found to be minimum at a low drill point angle (100°), high spindle rotation (2150 min−1 ), and low feed rate (0.025 mm/rev) due to reduced thrust force. The mean absolute prediction error was significantly improved considering root mean square torque rather than axial thrust with process variables.
Friction Stir Welding for Joining of Polymers Debasish Mishra, Santosh K. Sahu, Raju P. Mahto, Surjya K. Pal, Kamal Pal Lecture Notes on Multidisciplinary Industrial Engineering, 2019
Friction stir welding of polypropylene sheet Santosh K. Sahu, Debasish Mishra, Raju P. Mahto, Vyas M. Sharma, Surjya K. Pal, Kamal Pal, Susanta Banerjee, Padmanav Dash Engineering Science and Technology an International Journal, 2018
Experimental Study on the Feasibility of Friction Stir Lap Welding NK Goswami, RK Bisoyi, K Pal Advanced Joining Techniques: Proceedings of the AIMTDR 2023, 179 , 2026 2026
Integrated MCDM based optimization and sensitivity analysis of process signals in friction stir spot welding of dissimilar al 6061 to polycarbonate AK Pattanaik, T Barik, K Pal, RK Bisoyi, D Mishra Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2025 2025
Monitoring of Weld bead profile in friction stir lap welding for polycarbonate sheets using wavelet packets of power signal NK Goswami, K Pal, RK Bisoyi, SS Nayak Arabian Journal for Science and Engineering 50 (4), 2217-2249 , 2025 2025 Citations: 2
Weld quality monitoring in friction stir lap joining of dissimilar Al6061 to polycarbonate using thrust–torque-based process stability signatures NK Goswami, RK Bisoyi, K Pal Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2024 2024
Optimizing process parameters in drilling of CFRP laminates: a combined MOORA–TOPSIS–VIKOR approach T Barik, S Parida, K Pal Fibers and Polymers 25 (5), 1859-1876 , 2024 2024 Citations: 25
Sensor-based strategies for accurate prediction of drilled hole surface integrity of CFRP/Al7075 hybrid stack T Barik, K Pal, P Sahoo, K Patra Mechanics of Advanced Materials and Structures 31 (5), 1097-1124 , 2024 2024 Citations: 9
Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures AK Pattanaik, LP Nayak, RK Bisoyi, K Pal, D Mishra Proceedings of the Institution of Mechanical Engineers, Part C: Journal of … , 2024 2024 Citations: 2
Experimental Study on the Feasibility of Friction Stir Lap Welding of Polycarbonate to Al6061 Sheets NK Goswami, RK Bisoyi, K Pal All India Manufacturing Technology, Design and Research conference, 179-186 , 2023 2023
A Study on Friction Stir Lap Welding of Dissimilar Al 6061 to Polycarbonate NK Goswami, K Pal Advances in Additive Manufacturing and Metal Joining: Proceedings of AIMTDR … , 2023 2023
Investigation on tool positioning in friction stir lap welding of AA6061 to polycarbonate sheets using force-torque signals NK Goswami, LP Nayak, K Pal Journal of Adhesion Science and Technology 37 (9), 1543-1572 , 2023 2023 Citations: 8
Optimizing the input parameters setting for least hole defects while drilling CFRP laminates by multi-objective optimization on the basis of ratio analysis (MOORA) method T Barik, S Parida, K Pal Journal of Physics: Conference Series 2484 (1), 012007 , 2023 2023 Citations: 12
Application of ARAS Method for Finding Out the Best Possible Combination of Input Parameters for Least Hole Defects While Drilling CFRP Laminates T Barik, S Parida, K Pal NanoWorld J 9 (S1), S192-S197 , 2023 2023 Citations: 1
Joining of dissimilar thermoplastic polymers using friction stir processing: a review NK Goswami, LP Nayak, K Pal NanoWorld J 9 (S1), S72-S77 , 2023 2023 Citations: 1
Optimization of process variables in drilling of carbon fiber reinforced plastics using various multi criteria decision making approaches T Barik, K Pal Materialwissenschaft und Werkstofftechnik 54 (1), 45-68 , 2023 2023 Citations: 4
Performance analysis of hybrid ceramic insert in dry turning of hardened tool steel D Rath, S Panda, K Pal Arabian Journal for Science and Engineering 47 (12), 15455-15476 , 2022 2022 Citations: 6
Prediction of TiAlN-and TiN-coated carbide tool wear in drilling of bidirectional CFRP laminates using wavelet packets of thrust–torque signatures T Barik, K Pal Journal of the Brazilian Society of Mechanical Sciences and Engineering 44 … , 2022 2022 Citations: 25
Tribiological investigation and optimization of friction stir spot welding of dissimilar metals by LSSM-ANN method AK Pattanaik, K Pal, D Mishra Mechanics Based Design of Structures and Machines 50 (5), 1595-1613 , 2022 2022 Citations: 7
A comparative study between weldability of polycarbonate and nylon-6 using different pin geometries in friction stir welding SK Sahu, D Mishra, K Pal Proceedings of the Institution of Mechanical Engineers, Part B: Journal of … , 2022 2022 Citations: 15
Comparative assessment on weldability of Al 6061 to polycarbonate for dissimilar sheets placement in friction stir lap welding using sensor signals N Goswami, K Pal Proceedings of the Institution of Mechanical Engineers, Part C: Journal of … , 2022 2022 Citations: 22
Prediction of drilled hole quality in bidirectional woven carbon fiber reinforced plastic using wavelet packets of force–torque signals T Barik, K Pal Journal of Reinforced Plastics and Composites 40 (21-22), 800-826 , 2021 2021 Citations: 24
MOST CITED SCHOLAR PUBLICATIONS
Effect of pulse parameters on weld quality in pulsed gas metal arc welding: a review K Pal, SK Pal Journal of materials engineering and performance 20 (6), 918-931 , 2011 2011 Citations: 243
Investigation on arc sound and metal transfer modes for on-line monitoring in pulsed gas metal arc welding K Pal, S Bhattacharya, SK Pal Journal of Materials Processing Technology 210 (10), 1397-1410 , 2010 2010 Citations: 145
Friction stir welding of polypropylene sheet SK Sahu, D Mishra, RP Mahto, VM Sharma, SK Pal, K Pal, S Banerjee, ... Engineering science and technology, an international journal 21 (2), 245-254 , 2018 2018 Citations: 82
Monitoring of weld penetration using arc acoustics K Pal, SK Pal Materials and Manufacturing Processes 26 (5), 684-693 , 2011 2011 Citations: 82
Prediction of metal deposition from arc sound and weld temperature signatures in pulsed MIG welding K Pal, S Bhattacharya, SK Pal The International Journal of Advanced Manufacturing Technology 45 (11), 1113 , 2009 2009 Citations: 60
Friction stir welding for joining of polymers D Mishra, SK Sahu, RP Mahto, SK Pal, K Pal Strengthening and Joining by Plastic Deformation: Select Papers from AIMTDR … , 2018 2018 Citations: 54
Grey-Taguchi based optimizationof EDM process for titanium alloy M Priyadarshini, K Pal Materials Today: Proceedings 2 (4-5), 2472-2481 , 2015 2015 Citations: 42
Multi-sensor based prediction of metal deposition in pulsed gas metal arc welding using various soft computing models S Bhattacharya, K Pal, SK Pal Applied Soft Computing 12 (1), 498-505 , 2012 2012 Citations: 39
Study of weld joint strength using sensor signals for various torch angles in pulsed MIG welding K Pal, SK Pal CIRP Journal of Manufacturing Science and Technology 3 (1), 55-65 , 2010 2010 Citations: 38
Monitoring of friction stir welding for dissimilar Al 6063 alloy to polypropylene using sensor signals SK Sahu, K Pal, RP Mahto, P Dash The International Journal of Advanced Manufacturing Technology 104 (1), 159-177 , 2019 2019 Citations: 37
Soft computing methods used for the modelling and optimisation of Gas Metal Arc Welding: a review K Pal, SK Pal International Journal of Manufacturing Research 6 (1), 15-29 , 2011 2011 Citations: 35
Monitoring of hole surface integrity in drilling of bi-directional woven carbon fiber reinforced plastic composites T Barik, K Pal, S Parimita, P Sahoo, K Patra Proceedings of the Institution of Mechanical Engineers, Part C: Journal of … , 2020 2020 Citations: 29
Process parametric optimization in drilling of CFRP composites using GRA method T Barik, SK Jena, S Gahir, K Pal, SK Pattnaik Materials Today: Proceedings 39, 1281-1286 , 2021 2021 Citations: 26
Multi-objective optimisation of EDM process using hybrid Taguchi-based methodologies for Ti-6Al-4V alloy M Priyadarshini, K Pal International Journal of Manufacturing Research 11 (2), 144-166 , 2016 2016 Citations: 26
Optimizing process parameters in drilling of CFRP laminates: a combined MOORA–TOPSIS–VIKOR approach T Barik, S Parida, K Pal Fibers and Polymers 25 (5), 1859-1876 , 2024 2024 Citations: 25
Prediction of TiAlN-and TiN-coated carbide tool wear in drilling of bidirectional CFRP laminates using wavelet packets of thrust–torque signatures T Barik, K Pal Journal of the Brazilian Society of Mechanical Sciences and Engineering 44 … , 2022 2022 Citations: 25
Parametric study on joint quality in friction stir welding of polycarbonate SK Sahu, K Pal, S Das Materials Today: Proceedings 39, 1275-1280 , 2021 2021 Citations: 25
Prediction of drilled hole quality in bidirectional woven carbon fiber reinforced plastic using wavelet packets of force–torque signals T Barik, K Pal Journal of Reinforced Plastics and Composites 40 (21-22), 800-826 , 2021 2021 Citations: 24
Prediction of surface quality using chip morphology with nodal temperature signatures in hard turning of AISI D3 steel D Rath, S Panda, K Pal Materials Today: Proceedings 5 (5), 12368-12375 , 2018 2018 Citations: 24
Multisensor-based monitoring of weld deposition and plate distortion for various torch angles in pulsed MIG welding K Pal, S Bhattacharya, SK Pal The International Journal of Advanced Manufacturing Technology 50 (5), 543-556 , 2010 2010 Citations: 24
