Multi-Objective Modified Differential Evolution Methods for the Optimal Parameters of Aluminum Friction Stir Welding Processes of AA6061-T6 and AA5083-H112

This study introduces a modified differential evolution approach (MoDE) for evaluating the optimal objective and parameter values of friction stir welding (FSW) process dissimilar materials: AA5083 AA6061. The aim this is to investigate ultimate (UTS), maximum hardness (MH), minimum heat input (HI) weld zone. controlled parameters were shoulder diameter, rotation speed, tilt angle, pin type, reinforcement particle tool movement direction. D-optimal experimental design method was used create experiment obtain mathematical model optimizing targeted objectives. rotational pin-type, additive are 1162.81 rpm, 52.73 mm/min, 21.17 mm, 2.37 degrees, straight cylindrical, silicon carbide, direction, respectively. UTS, MH, HI 264.68 MPa, 105.56 HV, 415.26 °C, MoDE outcome exceeded swarm optimization (PSO), original algorithm (DE), (experiment) results. provides better than other approaches by an average 8.04%, 4.44%, 2.44%, In particular, when comparing results produced using various approaches, we discovered that 7.45%, 4.45%, 3.50% PSO, DE, results, All methods evaluated their reliability actual experiments those predicted theory, yielded smallest percentage difference between two, at 1.49%, while PSO DE differences 5.19% 3.71%,