Optimization of FSP parameters in fabricating AA5083/Coal composites using Taguchi method

Abstract This study investigates the optimization of Friction Stir Processing parameters to fabricate AA5083/Coal composites using the Taguchi method. The influence of key process parameters—tool tilt angle, tool rotation speed, and traverse speed—on the mechanical properties of the composites was evaluated, specifically focusing on ultimate tensile strength, microhardness, and elongation. Taguchi’s L 9 orthogonal array was employed to minimize the number of experiments and maximize the efficiency of parameter selection. A Hounsfield tensile test machine was used to evaluate ultimate tensile strength, and Innova Test Falcon 500 hardness testing machine was used to determine microhardness. The highest ultimate tensile strength, microhardness and percentage elongation achieved with the orthogonal arrays were 242 MPa, 96.27 HV, and 22.43%, respectively. The optimal parameters were identified as a tool tilt angle of 2°, a tool rotation speed of 900 rpm, and a traverse speed of 60 mm min −1 based on signal-to-noise ratio. Furthermore, an analysis of variance was conducted to evaluate the parameter contributions. Analysis of Variance revealed that rotational speed had the most significant impact on microhardness and percentage elongation, while tilt angle most strongly influenced ultimate tensile strength. This study demonstrates the viability of coal particles as a cost-effective reinforcement material for AA5083 composites and provides a robust framework for optimizing friction stir processing parameters using statistical methods.