Statistical modeling of friction stir welding process parameters using TOPSIS and ANOVA

Abstract This study explores the multi-objective optimization of friction stir welding (FSW) process parameters to improve the mechanical characteristics such as tensile strength, microhardness, and impact strength of AA5052-H32 and AA6082-T6 dissimilar FSW joints. The experimental results were ranked and evaluated using the taguchi technique in convergence with the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) methodology. The welding speeds (WS) of 20, 25, and 30 mm min −1 , the tool rotational speeds (TRS) of 1000, 1100, and 1200 RPM and the tool tilt angle (TTA) of 0°, 1°, and 2° were used as the input parameters in the trials. At a TRS of 1200 RPM and a WS of 25 mm min −1 , the experimental results indicate a consistent rise in microhardness and tensile strength values with increasing TRS, reaching peak values of 72 HV and 188 MPa, respectively. Conversely, the impact strength reflected a decreasing trend, with a maximum value of 44 Joules at a TRS of 1000 RPM. This work delivers insightful information for the marine and aerospace sectors in pursuit of rigid and high-performance weld structures.