Optimization of Dissimilar AA5052 and AA2219 Alloy Joints in Friction Stir Welding Using Taguchi Grey Relational Analysis

Abstract

Friction stir welding (FSW) is a new type of welding that is widely used in the automotive and manufacturing industries. The purpose of this work is to maximize the strength of dissimilar welded connections by examining how tensile strength is affected by tilt angle, axial force, welding speed, and rotating speed. The current study investigates the effect of rotational speed, welding speed, axial force, and tilt angle on the output response of tensile strength; these parameters were also studied with the use of a surface plot and a contour plot. The AA5052 and AA2219 alloys are chosen as the workpiece material due to their usefulness in a variety of settings. Materials are sized and shaped in accordance with the criteria of ASTM standard. Each output response is then assessed across all welding conditions when the tests are completed. The Taguchi L9 orthogonal array (OA) will be used to guide the planning of the experimental design. Taguchi based Grey relational analysis (GRA) was used to the experimenting data in order to optimize the multi-responses. Using the GRA method, numerous responses in an FSW approach may be optimized simultaneously. During GRA optimization, S/N ratios, Grey relational coefficients (GRC), and Grey relational grades (GRG) are calculated, with the latter used to establish ranks. In most cases, this strategy works well for enhancing the various results produced by the FSW approach.