Optimization of FSW parameters on bio-inspired jigsaw suture patterns to improve the tensile strength of dissimilar thermoplastics

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This study aimed to enhance the Tensile Strength (TSFSW) of dissimilar thermoplastic joints by utilizing a bio-inspired jig saw suture and optimizing the Friction Stir Welding (FSW) limits are Traverse Speed (TS) and Plunge Depth (PD) and Rotational Speed (RS) at three varied levels. Statistical analysis, response surface methodology (RSM), and experimental validation were involved in achieving the research objectives. The outcomes showed that the TS and PD parameters had a higher significance on Tensile Strength compared to RS. The RSM prediction results were validated through experiments, achieving an extreme Tensile Strength of 11.1 MPa with a low error percentage. The best values of the FSW limits were found to be Rotational Speed (RS) of 1200 rpm, Plunge Depth (PD) of 0.37 mm, and Traverse Speed (TS) of 49.39 mm min−1. The formulated mathematical model with regression co-efficient R2 of 0.96 and RSM proved effective in predicting the optimal FSW parameters and achieving superior TSFSW. These findings prove that combination design can be reliably applied to optimise with a 95% confidence interval. The optical microscope and SEM morphological results in this study make congruently accurate predictions for the joint of the tensile fracture zone. These findings contribute to the advanced FSW techniques for dissimilar thermoplastic joints, providing insights for industrial applications requiring strong and reliable joints.