Abstract
The development and demand for lightweight materials such as aluminum, magnesium, and their alloys have been significant in the aerospace and automotive industries. Friction stir welding (FSW) is an economical solution for establishing a good joint for these metals and their alloys. In the current investigation, the aluminum alloy plates of AA6063 were fused using underwater FSW using a D2 steel tool holder and an HSS tool with a conical pin. According to Box Behnken design (BBD), the welding experiments were based on Response Surface Methodology (RSM) with 15 tests. The process constraints were controlled by the Combined Compromise Solution (CoCoSo) based optimization module. The influence of transverse speed (TS), rotational speed (RS), and pin length (Pl) on mechanical performances such as Ultimate tensile strength (UTS) and hardness test (HRB) is investigated. The analysis of variance (ANOVA) demonstrated that the transverse speed, rotational speed, and pin length are the essential factors in determining joint soundness. After performing the confirmation run with the optimal parameters, the predicted optimal value of the welding response was verified. This study indicates that the proposed optimization module efficiently controls the varying process parameters to achieve conflicting response values. It is highly efficient to manufacture high-efficiency welded joints and is recommended for optimum joint qualities.
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