Optimization on the Tool Parameters in Friction Stir Lap Joining of AA2219 by Response Surface Methodology

Abstract

The friction stir welding (FSW) tool's ability to generate heat and strain is crucial to the process's overall performance while performing welding. This study used the RSM to analyse the effects of shoulder diameter, pin diameter and pin height on the temperature, forces and failure load experienced during FSW of AA2219 alloy. There were three components, three stages and seventeen different iterations in this study. A thermocouple was embedded into the samples to measure the welding temperature. In addition, a force measuring device was used to track the amount of pressure applied during the procedure. Using an analysis of variance, it was determined whether or not the resulting model was suitable at 95% confidence level. Through RSM, a correlation was found between tool settings and other input factors and the resulting temperature, force and mechanical qualities of the joints. Afterwards, the optimal processing factors were found by employing a hybrid multi objective optimization based on this connection. According to hybrid multi objective optimization, the best dimensions for a probe are 5.1mm in diameter, 18.43mm in shoulder diameter and 4.12mm in height. Temperature, force and failure load were found to be most affected by shoulder diameter, probe diameter and probe height.