Multi-Response Optimization of Process Parameters in Friction Stir Welding of AA 8011-H14 / AA 5052-H34 using Taguchi Grey Relational Analysis

Abstract

Friction stir welding (FSW) offers a distinct advantage in its ability to effectively join dissimilar metals and alloys. This study focuses on the butt welding of AA 8011-H14 and AA5052-H34 through FSW, aiming to explore the influence of process parameters on crucial mechanical properties such as ultimate tensile strength, yield strength, percentage elongation, and hardness. The examination of the welded cross-section revealed variations in both grain orientation and size across different zones. Notably, most failures were identified at the base of AA8011-H14 on the Advancing side. Furthermore, the hardness of the nugget zone exhibited variability based on the material ratio mix, with the maximum hardness observed on the AA5052-H34 side. Comparisons of optimal joint efficiencies were made to assess the overall effectiveness of the welded joints. This investigation contributes valuable insights into the intricacies of FSW when applied to dissimilar metal combinations, shedding light on the impact of process parameters on the mechanical characteristics of the joints.