Multi-Objective Optimization of Friction Stir Welding for Aluminum Alloy (2024-T3)

Abstract

In this research, a multi-response optimization based on Taguchi method is proposed for friction stir welding (FSW) process for (2024-T3) aluminum alloy. Three different shoulder diameters of tools with tapered pin geometry of (12, 14 and 14 mm) with variable rotation speed (710, 1000 and 1400 rpm) and welding speed of (40, 56 and 80 mm/min), three different tilting angles of (1, 2 and 3 degree) and three welding direction of (1, 2 and 3 passes). The results of this work showed the single optimization by using (Taguchi method) at the optimum condition for the tensile strength and yield strength were (365 MPa) and (258 MPa) respectively; at the parameters: shoulder diameter (14 mm), rotation speed (1400 rpm), linear speed (40 mm/min), tilting angle ((3°) for tensile strength and (1°) for yield strength) and welding direction (3 passes). The results of multi-response optimization for (FSW) process at the optimum condition for tensile strength and yield strength were (371 MPa) and (268 MPa), respectively; at the parameters: shoulder diameter (14 mm), rotation speed (1400 rpm), linear speed (40 mm/min), tilting angle (3°) and welding direction (3 passes).