Abstract

In this study, two dissimilar materials (Al 5052 and AZ31) have been welded using the Friction stir process (FSW). Taguchi’s philosophy has been used to design the experiment using four input parameters (Tool types (TP), Tool traverse speed (TTS), Tool tilt angle (TTA), and Tool rotation Speed (TRS)). The machining performances have been identified using ultimate tensile strength (UTS) and Vickers hardness (HV). The models are evaluated for sufficiency, and then the most significant parameters are determined using analysis of variance (ANOVA). The ANOVA results revealed that TTS has a maximum contribution of 50.2% and 46.5% towards obtaining the high UTS and HV, respectively. The mathematical model using the non-linear model for UTS and HV has been created to predict the mechanical properties of FSWed joints. The prediction welding accuracy of a multi-objective optimization has been performed using the Multi-Objective Dragonfly Algorithm (MODA). The adopted strategy shows a high welding accuracy with minimum computational time.

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