Optimization of process parameters for friction stir welding of dissimilar aluminum alloys using different Taguchi arrays

Abstract A statistical optimization based on experimental work was conducted to consider ultimate tensile strength (UTS) and elongation of dissimilar joints between AA5454 AA7075 by friction stir weld (FSW). The goal this is develop a comparative study the FSW parameters using different orthogonal arrays, i.e., L12 L16. Four correlated softening forging requirements (rotational speed, traverse tilt angle, plunge depth), one parameter associated with location base metal in joint, two related an tool (pin profile D shoulder /d pin ratio) were considered arranged employed arrays. Moreover, investigation explored microstructure fractography metals optical scanning electron microscopes. results showed that L16OA more accurate than L12OA for seven due small errors. For UTS, errors range from 0.78 24% 27.23 44.14% L12OA. elongation, run 11 12.9% 33.77 49.73% accuracies generated models 50 99.5% 30.7 94.9% Tightening levels (narrow domain) main reason switching some optimum both highest UTS obtained 221 MPa attained L16OA, 12.83% according acquired Despite deficiency effective intermixing, revealed acceptably could assemble AA7075, presenting proficiency welding aluminum alloys.