Optimization of Process Parameters for Friction Stir Welding of Different Aluminum Alloys AA2618 to AA5086 by Taguchi Method

Friction stir welding (FSW) was used to combine two different Al–Cu alloys, AA2618-T87 and Al–Mg alloy AA5086-H321 plates, and the characteristics of the procedure were adjusted using Taguchi L16 orthogonal experiments planned in advance. Consideration was given to a variety of factors including rotational and cross-sectional speeds, geometry, and the tool-to-pin-diameter ratio. The tensile strength of the joint was used to identify the best procedure parameters. Runs with the ideal settings confirmed the projected optimal tensile strength value. A wide range of process parameters can be used to generate high-quality joints, according to this study. According to the results of an analysis of variance, the most important factor in determining the soundness of a joint is the fraction of tool contact area to pin diameter, although pin shape and welding speed also have a major impact. During this examination, it was observed that the nugget region is dominated by material on the forward-moving side. Heat-affected zones with tensile failures occurred on the alloy 5086 side of the weldment.