Optimization of GMAW parameters for AA7075 T6 aluminum alloy using Rao algorithms

This study introduces a multi-objective optimization method to find the optimal process parameters for Gas Metal Arc Welding (GMAW) of AA7075 T6 aluminum alloy. The approach leverages Rao algorithms to enhance welding performance and quality. AA7075 T6 is a high-strength aluminum alloy commonly utilized in aerospace and automotive applications, presenting challenges in achieving optimal welding parameters due to its susceptibility to heat-induced distortion and porosity formation. This research aims to find the optimal combined values of welding parameters that result in enhanced weld quality and improved mechanical properties. The optimization process begins with a comprehensive understanding of AA7075 T6 material properties and GMAW process variables. Design of Experiments methodology is employed to systematically vary welding parameters like voltage, current, wire feed rate, travel speed, and gas flow rate. In this work, three algorithm-specific, parameter-less, and effective Rao algorithms are utilized to find the optimal set of GMAW parameters. Three process parameters affecting bead geometry, such as bead width, bead height, and bead penetration, are considered as objectives. This work aims to optimize input process parameters for the GMAW process of AA7075 T6 aluminum alloy material. Results obtained from the optimization process demonstrate significant improvements in weld quality compared to baseline parameters. The implementation of the optimized welding parameters enhances the manufacturability and performance of welded AA7075 T6 components, contributing to advancements in aerospace and automotive engineering.