Using Six Sigma Methodology to Improve Friction Stir Welding of Aluminum Pipes

Author(s): El-Kassas A. M.1, Sabry I.2

1 Tanta University, El-Gaish, Tanta Qism 2, Tanta, Gharbia Governorate, Egypt;
2 Modern Academy for Engineering and Technology, El-Hadaba El-Wosta-Elmokattam, Egypt

*Corresponding Author’s Address: [email protected]

Issue: Volume 5; Issue 2 (2018)

Paper received: March 8, 2018
The final version of the paper received: August 13, 2018
Paper accepted online: August 18, 2018

El-Kassas A. M. Using Six Sigma Methodology to Improve Friction Stir Welding of Aluminum Pipes / A. M. El-Kassas, I. Sabry // Journal of Engineering Sciences. – Sumy : Sumy State University, 2018. – Volume 5, Issue 2. – P. B1-B8.

DOI: 10.21272/jes.2018.5(2).b1

Research Area: MANUFACTURING ENGINEERING: Technical Regulations and Metrological Support

Abstract. This paper presents a novel welding quality evaluation approach based on the analysis of IMR and process capability for friction stir welding. The method has been implemented in an experimental work developed using the rotation speed range was from 485 to 1 800 rpm with a travel speed travel speed range from 4 to 10 mm/min. This ranges applied with different material thicknesses from 2 to 4 mm. This research approach to DMAIC (“define – measure – analyze – improve – control”) analysis to attachment potency and technical commonplace demand. The analysis controlled the tensile strength, elongation and hardness of the Al 6061 friction stir welded joints. Friction stir welding process has three main variables: rotation speed, material thickness and travel speed. Different friction stir welded samples were produced by changing these three variables. The result was improving the values of the process capability index Cpk from (0.86, 0.37, 0.81) to (0.69, 0.57, 0.58) for the tensile strength, elongation and hardness respectively.

Keywords: Six Sigma, DMAIC, pipe welding, tensile strength, elongation, hardness.


  1. Desai, T. N., & Shrivastava, R. L. (2008). Six Sigma – A New Direction to Quality and Productivity Management. Proceedings of the World Congress on Engineering and Computer Science.
  2. Shinde, M. S., & Inamdar, K. H. (2014). Reduction in Tig Welding Defects for Productivity Improvement Using Six Sigma. International Journal of Technical Research and Applications, Vol. 2, Issue 3.
  3. Thakar, S. P., Dinesh, K. P., & Pradeshi, R. (2015). An Implementation Of Six-Sigma In Steel Tube Welding: A Case Study. International Journal of Innovative Science, Engineering and Technology, Vol. 2, Issue 9.
  4. Womack, J. P., & Jones, D. T. (2003). Lean Thinking: Banish Waste and Create Wealth in Your Corporation. Simon & Schuster Publishing.
  5. Byrne, G., Lubowe, D., & Blitze, A. (2007). Driving Operational Innovation using Lean Six Sigma. IBM Institute for Business Value.
  6. Krunal, S., & Pathak, A. (2014). Reduction of Non Conformative Rate of Bearing Rings Using Six Sigma Methodology. International Journal for Research in Applied Science and Engineering Technology, Vol. 2, No. V, pp. 532–539.
  7. Ropp, T. D., Dubikovsky, S., & Johnson, M. E. (2010). Using Peer and Team Performance Assessments as Learning Tools on Collaborative Student Projects. Journal of Aviation/Aerospace Education and Research, Vol. 2, No. 2 , pp. 627–631.
  8. Kwak, Y .H., & Anbari, F. T. (2006). Benefits, Obstacles, and Future of Six-Sigma Approach. Technovation, Vol. 26, No. 1, pp. 708–715.
  9. Soni, S., Mohan, R., Bajpai, L., & Katare, S. K. (2013). Optimization of Submerged Arc Welding Process Using Six Sigma Tools. International Journal of Modern Engineering Research, Vol. 3, Issue 3, pp. 1690–1696.
  10. Eckes, G. (2001). The Six Sigma Revolution: How General Electric and Others Turned Process Into Profits. Wiley, Vol.14, No.1.

Full Text