Optimizing friction stir welding parameters for enhanced mechanical properties of dissimilar aluminum alloys AA5083 and AA6063: A Taguchi approach

This study aims to optimize Friction Stir Welding (FSW) parameters to improve the mechanical properties of AA5083-AA6063 aluminum alloy joints, which are crucial for applications requiring high strength and durability. A Taguchi L9 orthogonal array experimental design was employed to systematically vary three key parameters: rotation speed, travel speed, and tool-pin taper angle, with the objective of maximizing tensile strength and hardness. The results demonstrated that a moderate rotation speed combined with a larger tool-pin taper angle produced optimal outcomes, achieving a tensile strength of 215.40 MPa and a hardness of 90.69 HV. Statistical analyses using signal-to-noise ratios and Analysis of Variance (ANOVA) identified rotation speed as the most influential factor affecting both tensile strength and hardness, followed by tool-pin taper angle, while travel speed had a minimal impact. Microscopic examinations revealed that the optimized settings yielded defect-free welds with ductile fracture patterns. These findings underscore the critical importance of precise FSW parameter selection in enhancing weld quality and contribute valuable insights for advanced manufacturing applications in industries requiring robust aluminum alloy joints.