AA6061 Alloy Research Articles

A Modified Johnson Cook Model-Based Kalman Filter Method to Determine the Hot Flow Behavior of Sustainable AA6082 Al Alloy

AA6082 alloys play a significant role in advancing sustainable development goals (SDGs) by contributing to environmental sustainability, economic growth, and social well-being. These alloys are highly recyclable and align with SDG 12 by promoting resource efficiency and reducing waste. Their application in lightweight vehicles and improving energy efficiency in construction supports SDG 9 and SDG 11, as they help reduce carbon emissions and enhance the sustainability of urban environments. While AA6082 alloys offer significant advantages, their use has limitations that can hinder their industrial applications. One key challenge is their lower formability, particularly at room temperature. Elevated-temperature deformation is frequently employed to enhance the formability of these alloys and address their limitations. Thus, a deep understanding of the constitutive analysis of these alloys under a wide range of T and ε is essential for manufacturing sound components from these alloys. Thus, this study aims to propose a new modification for the JC model (PJCM) and compare its reliability to predict the warm/hot flow behavior of AA6082 alloys with that of the original JC model (OJCM) and the modified JC model by Lin et al. (LMJCM). By comparing the experimental results with these model results and confirming the determining correlation coefficient (R), average absolute relative error (AARE), and root mean square error (RMSE) values, it is concluded that the stresses predicted by the PMJCM closely match the experimental stresses of the LMJCM and OJCM because of the interaction between ε, ε, and T, which might be a reason for the complex nonlinear behavior of AA6082 alloys during hot deformation.

Effect of high pressure-low plasticity burnishing on the mechanical and microstructural behaviour of copper foil interlayered FSW aluminium alloys

Abstract This study delves into the impact of high pressure-low plasticity burnishing (HP-LPB) on the mechanical and microstructural behaviour of friction stir welding (FSW) joints, specifically involving AA5052 and AA6082 aluminium alloys. Notably, copper foil (CF) is introduced as a novel element in the HP-LPB process to enhance the weld strength. The experiments were conducted with the tool rotational speeds (TRS) of 1000, 1100, and 1200 RPM, each paired with the welding speeds (WS) of 20, 25, and 30 mm min−1, and tool tilt angle (TTA) of 0°, 1°, and 2°. Mechanical behaviour is assessed through tensile testing along with microhardness measurements, revealing the advantages of HP-LPB with CF in enhancing joint strength and toughness. The microstructural analysis reveals the dissolution of precipitates, highlighting the influential role of copper foil in the improvement of joint efficiency. From the weld without a CF interlayer, a maximum tensile strength of 188 MPa was achieved at a TRS of 1200 RPM, WS of 25 mm min−1 and TTA of 2°. The post-processed FSW sample interlayered with copper foil, exhibited an improvement in joint efficiency by 87% at the optimum process parameter. This research demonstrates that the use of copper foil interlayers combined with HP-LPB treatment can substantially enhance the mechanical properties and structural integrity of FSW aluminum alloys, offering a valuable solution for advanced industrial applications.

Predicting the Tensile behavior of AA7075 Alloy Processed through Powder Metallurgy Process

Predicting the Tensile behavior of AA7075 Alloy Processed through Powder Metallurgy Process

Elucidating the effect of strain path-dependent crystallographic texture evolution on the electrochemical behavior of nanostructured AA2024 aluminum alloy

This research provides insight into the effect of strain path-dependent texture evolution on the electrochemical behavior of nanostructured AA2024 aluminum alloy in a phosphate buffer solution (pH = 8.3). To achieve this, AA2024 alloy sheets were processed using two methods: accumulative roll bonding (ARB) and cross accumulative roll bonding (CARB), i.e., rotating the sheets 90° around the normal direction (ND) axis between each cycle. The ARB-processed AA2024 alloy exhibited a pancake-shaped structure and included texture components of Copper {112}<111>, Brass {011}<211>, P {110}<221>, and S {123}<634>. Meanwhile, the CARB-processed AA2024 alloy had extremely fine and equiaxed nano-grains (< 100 nm) and texture components of S {123}<634>, Brass {011}<211>, Goss {011}<100>, Rotated Cube {001}<110>, and P {110}<221> after eight cycles. Electrochemical studies demonstrated an increase in corrosion current density due to high imposed strains in the ARB route, which in effect made the conditions of passive layer formation more difficult and lowered the corrosion resistance. Additionally, achieving a more uniform distribution of extremely fine grains and {011} orientation textures such as Brass {011}<211>, Goss {011}<100>, and P {110}<221> texture components in the CARB route, provided ideal conditions for forming oxide passive films with superior protection properties compared to ARB. These unique findings can contribute to the broader application of crystallographic-orientation-dependent electrochemical behavior of alloys in the field of corrosion management.

Parametric analysis of electrical discharge machining on AA6061 with a WC–Cu composite electrode

The AA6061 aluminium alloy surface characteristics presented in this study were obtained after it was machined using die sinking electro discharge machining (EDM) with a composite electrode developed through powder metallurgy. Machining was performed using negative polarity. In order to obtain optimum material removal rate (MRR) and surface roughness (SR), the research has been carried out, and EDM parameters like voltage, current and pulse on time were optimized using the response surface methodology that integrates the central composite design. The parameter interaction effects on EDM machined surface characteristics were studied with the aid of ANOVA. It was determined from model that the regression for MRR and SR were 98.6% and 98.3% respectively, means empirical model is considered sufficient. It was observed that increased MRR and SR were observed in the condition of increased current, but MRR and SR decreased at increased voltage and pulse on time. This could be due to strengthened ionization temperature that increased MRR with acceptable SR. The microstructure of the machine was assessed using microscopic evaluation. The increased current contributed to the formation of a recast layer and debris which hinders the machining process and reduces MRR. The experimental results show that the maximum MRR of 0.087 mg/min and minimum SR of 1.893 µm were achieved. Additionally, the use of WC–Cu composite electrodes led to an increase in hardness from 65 HV to 78 HV in the machined region. It is concluded that WC–Cu composite electrodes typically result in higher hardness, improved MRR and better SR for the AA6061 alloy compared to conventional Cu electrodes.

Influence of multiple friction stir welding passes on the microstructure and mechanical properties of AA2024 age-hardened aluminum alloy

Friction stir welding (FSW) is a promising joining process for age-hardened aluminum alloys. However, when the process is used for welding age-hardened aluminum alloys, the hardness and joint efficiency are poor mainly because the strengthening precipitates become incoherent and/or get dissolved during the welding process. In this novel work, efforts have been made to enable the reprecipitation of the strengthening precipitates using multi-pass FSW. After producing FSW welds on AA2024 alloy, the welds have been processed by the same tool and at the same parameters several times to facilitate the reprecipitation of strengthening precipitates. As the precipitation kinetics of age-hardened aluminum alloys are temperature-dependent, a thermal imaging camera was utilized to record the temperature history during welding and subsequent cooling of the welded plates. The metallurgical examination of welded samples was carried out using optical microscopy, Scanning Electron Microscope (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), and microhardness test. It was observed that grain refinement occurs continuously due to dynamic recrystallization and severe plastic deformation up to the third FSW pass, after which there is no significant change in grain size. Generally, the microhardness value was higher in the stir zone than the heat-affected zone (HAZ), and the hardness in the stir zone increased after 4 passes of FSW. SEM images show clusters of incoherent precipitates, fragmentation, precipitate dispersion, dissolution, and reprecipitation of precipitates during each subsequent pass. The identification of the precipitates was carried out using EDS and XRD analysis.

Analyzing the Influence of Titanium Content in 5087 Aluminum Filler Wires on Metal Inert Gas Welding Joints of AA5083 Alloy

As the demand for lightweight structures in the transportation industry continues to rise, AA5083 aluminum alloy has become increasingly prominent due to its superior corrosion resistance and weldability. To facilitate the production of high-quality, intricate AA5083 components, 5087 aluminum filler wire is commonly utilized in metal inert gas (MIG) welding processes for industrial applications. The optimization of filler wire composition is critical to enhancing the mechanical properties of AA5083 MIG-welded joints. This study investigates the effects of modifying 5087 aluminum filler wires with different titanium (Ti) contents on the microstructure and weldability of AA5083 alloy plates using MIG welding. The influence of Ti contents was systematically analyzed through comprehensive characterization techniques. The findings reveal that the constitutional supercooling induced by the Ti element and the formation of Al3Ti facilitate the heterogeneous nucleation of α(Al), thereby promoting grain refinement. When the Ti content of 5087 filler wire is 0.1 wt.%, the grain size of the weld center was 78.48 μm. This microstructural enhancement results in the improved ductility of the AA5083 MIG-welded joints, with a maximum elongation of 16.64% achieved at 0.1 wt.% Ti addition. The hardness of the joints was the lowest in the weld center zone. This study provides critical insights into the role of Ti content in MIG welding and contributes to the advancement of high-performance filler wire formulations.

Gray relational analysis for parametric optimization of micro-EDM of thermo-mechanically processed AA7075 and AA7075/SiC/Gr composite

The AA7075 alloy and AA7075/SiC/Gr hybrid composite prepared by the stir-casting method have been further thermo-mechanically processed through unidirectional hot rolling and hot cross-rolling routes to eliminate casting defects like voids, blow holes etc. Three initial sample temperatures, that is, 350℃, 400℃, and 450℃, have been considered for the hot cross-rolling. The Al alloy and its hybrid composite prepared at different rolling temperatures are studied to investigate their micro-machining behavior through micro-electric discharge machining (µ-EDM). The micro-holes are made on the rolled samples along the rolling direction of the final rolling pass using a tool with twist drill bit geometry. Further, multi-objective optimization of the µ-EDM process parameters considering the response parameters viz. material removal rate (MRR) and tool wear rate (TWR) has been carried out using the gray relational analysis (GRA) technique. The µ-EDM parameters chosen to optimize in this study are voltage, pulse on time, and tool rotation. The obtained GRA results are further analyzed through normality and equal variance tests. The R-squared values of 95.02% and 95.53% for AA7075 alloy and hybrid composite, respectively, indicate that the data fit well with the statistical model. In material removal, the different electrical and thermal characteristics of the Al matrix and the reinforcements possibly generate sparks with a different characteristic that ultimately affects the MRR of the composite. Through scanning electron microscopy (SEM), the morphological study confirmed the presence of globules and voids on the machined surface. The formation of globules and voids is more significant in the AA7075 alloy than in the composite.

Effect of quenching protocols on microstructure and corrosion morphology in a recycled Al–Mg–Si alloy: Tracing Cu impurities

In the present work, three different quenching protocols - water quenching (WQ), forced air quenching (FAQ) and air quenching (AQ) - were utilized to tailor the intragranular and intergranular preference of Cu impurities in a recycled AA6082 alloy. It is found that Cu tends to be incorporate in the precipitates at grain boundaries in the WQ-treated alloys. However, both AQ and FAQ protocols interestingly eliminate such intergranular Cu enrichment, consequently sequestering Cu solutes in (Mg, Si)-rich precipitates in grain interiors. As the quenching rates decrease, the FAQ- and AQ-treated alloys resultantly exhibit a positive shift in pitting potential, which is accompanied by a transition in corrosion morphology from boundary attack to pitting, with a notable reduction in corrosion depth.

Corrosion inhibitor from nature: Fundamentals of tannic acid inhibition for AA2024 alloy

This study addresses the fundamentals of corrosion inhibition of AA2024 alloy by tannic acid (TA), a Cr-free and eco-friendly natural product. To this end, the AA2024 alloy was immersed in NaCl solution (50 mM) with different TA concentrations (0.1–10 mM) for 7 days. Surface (SEM, Raman, and SKPFM) and electrochemical analyses (EIS, PDP, and SVET) revealed mixed inhibition after 1 day of immersion in TA solution. Long-term immersion tests in TA solutions produced a tannate-rich oxide film on the surface. The films with low tannate content (formed in 0.1 and 1 mM TA) showed the highest stability and corrosion resistance.

Impacts of T6 heat treatment on the microstructural, mechanical, and corrosion properties of thixoformed AA7075 alloy produced by cooling slope casting

Abstract Research into semi-solid metal forming techniques has been ongoing for an extended period with the aim of producing near-net shape products from aluminum alloys. The primary focus has traditionally been on casting alloys seeking to offer an alternative to the other processes such as high pressure die casting. Over the past twenty years, wrought aluminum alloys have also been explored for thixoforming operations as an alternative to traditional plastic deformation techniques. This research investigated the impacts of T6 heat treatment on the microstructural, mechanical, and corrosion properties of AA7075 alloy samples produced through cooling slope casting and subsequent thixoforming with different reheating durations. The selected alloy was chosen due to its widespread use in various industries, attributed to its excellent strength-to-density ratio achieved after T6 heat treatment. Building on optimized cooling slope casting parameters from a prior study, the standard solution treatment procedure following thixoforming with extended reheating times was found to be inadequate. Hardness and tensile tests revealed that specimens reheated for 120 min exhibited significantly reduced response to T6 treatment. Despite achieving the targeted hardness value of 154 HB with samples reheated for 20 min prior to thixoforming and T6 heat treatment, especially the elongation at break values were unsatisfactory. Potentiodynamic polarization tests indicated that corrosion primarily involved grain dissolution, with longer reheating times decreasing corrosion resistance due to increased amount of secondary phases and grain isolation. These findings highlight that while AA7075 alloy can be processed into semi-solid formable materials via cooling slope casting, issues such as hot tearing, micro-shrinkage, and physical defects post-thixoforming hinder the achievement of desired tensile properties.

Efficient optimization of friction stir welding parameters for AA7075 and AA6082 alloys: A Hungarian method approach

Friction stir welding (FSW) is a key technique for welding high-strength aluminium alloys without melting, making it indispensable in industries where maintaining material integrity is of utmost importance. The current study presents a novel application of the Hungarian method, a combinatorial optimization technique, to determine the optimal FSW parameters for AA7075 and AA6082 alloys. The weldments were produced by applying different feed rates (40, 50 and 60 mm/min) and rotational speeds (1000, 1100 and 1200 rpm) in accordance with a L9 orthogonal array. The optimal combination was, a feed rate of 40 mm/min and a rotational speed of 1200 rpm, yielding an ultimate tensile strength of 162.26 MPa, a percentage elongation of 2.56 and an impact energy of 2.5 J/mm². The microstructural investigation showed substantial improvement in the grain refinement of the weld nugget, which significantly contributed to improved mechanical properties. However, under optimal welding conditions, the weld nugget exhibited a significant negative corrosion potential compared to the base metals, indicating a higher susceptibility to corrosion. These results show that the Hungarian method provides a systematic approach to optimizing FSW parameters, but it might be necessary to adapt post-weld treatment to lower propensity to corrode. This study illustrates not only the application of the Hungarian method in the optimization of operating parameters of FSW but also establishes a base for further studies dealing with combinatorial optimization problems in welding and other manufacturing processes.

Nanoparticle-enabled additive manufacturing of high strength 6061 aluminum alloy via Laser Powder Bed Fusion

Wrought aluminum alloy AA6061 is widely used in automotive, aerospace, and other industries due to its good properties, including high strength, excellent corrosion resistance, and good weldability. However, when using Laser Powder Bed Fusion (LPBF) for AA6061, hot cracking becomes a serious problem. In this work, AA6061 powder with internally dispersed nanoparticles has been adopted in a LPBF process. Through optimization of printing parameters, components with minimal porosity (less than 0.5 %) have been successfully produced without cracks. Additionally, by employing a chessboard printing strategy to create finely detailed cellular and grain structures, we have achieved significantly enhanced mechanical properties in its as-printed state for AA6061. These components exhibit an impressive yield strength (YS) of 233 MPa and ultimate tensile strength (UTS) of 310 MPa while maintaining a ductility of approximately 10 %. This performance surpasses that of commercial AA6061 and other Al-Si alloys, establishing it as a high-strength material suitable for various applications.

Sustainable development of agro bio-mass waste based AA6061-Tungsten carbide hybrid reinforced composites: A comprehensive performance investigation

The Recycling, Reusing, and Reduction (3R) strategy to solid waste management is proposed for exploiting the functionalities of wastes in enhancing base material performance, which could contribute to produce a sustainable product and environment. This study investigates the impact of organic and synthetic ceramic reinforcements; coconut shell ash (CSA), and tungsten carbide (WC) at various concentrations (1, 2, and 3 wt. % each) on microstructural and performance characteristics of sustainable AA6061 based hybrid composites. The composites are produced via the stir casting process with mechanized stirring. The microstructural characteristics of the produced aluminium hybrid composites (AMHC) are evaluated by FESEM/EDAX, FT-IR and XRD studies to examine their elemental composition, morphology and crystalline nature. The mechanical properties are investigated by charpy impact, tensile, compressive and micro-harness studies. The density and porosity analysis are employed to ascertain their physical characteristics. Morphology investigations show that the selected reinforcing materials are present and uniformly dispersed across the matrix's surface. The produced composite with 4 wt. % of CSA and WC reinforcements has the ability to improve the hardness (75.5 %), tensile strength (42.87 %), and compressive strength (55.71 %) of the base Aluminium alloy. Overall, using organic and synthetic ceramic substances as reinforcements for AA6061 alloy can result in sustainable high-performance composites for structural engineering applications across fields.

Maximizing machining efficiency and quality in AA7075/Gr/B4C HMMCs through advanced DS-EDM parameter optimization strategies

Abstract Hybrid Metal Matrix Composites (HMMC) offer improved mechanical properties crucial for various industrial applications. However, machining these composites via traditional methods is arduous due to their inherent hardness and abrasive nature. The optimization of the Die-Sinking Electrical Discharge Machining (DS-EDM) process presents a viable solution to overcome these machining challenges and unlock the full potential of HMMCs. Despite the potential benefits of HMMCs, the lack of optimized machining strategies hampers their widespread adoption in industrial applications. Traditional machining approaches often result in excessive tool wear, poor surface finish, and suboptimal material removal rates (MRR) when applied to HMMCs. Additionally, the complex interplay between DS-EDM process parameters and material properties necessitates a systematic investigation to identify optimal machining conditions. This study proposes a multi-step methodology to systematically optimize the DS-EDM process for machining HMMCs comprising AA7075 alloy, 5% of graphite (Gr), and 5% of boron carbide (B4C) particles, which is termed as (AA7075-GR-B4C). Beginning with the formulation of the composite material through stir casting, the research progresses to an L16 Orthogonal Array (L16-OA) based Design of Experiments (DoE) to investigate the effects of key process parameters on machining performance. Experimental testing is conducted to measure mechanical properties, followed by statistical analysis using Analysis of Variance (ANOVA) with Regression Analysis to identify significant factors influencing machining outcomes. Furthermore, an Artificial Neural Network with Black Widow Optimization (ANN-BWO) approach is employed to optimize machining performance metrics such as MRR, Surface Roughness Rate (SRR), and Tool Wear Rate (TWR). The Relative Error (RE) was estimated between experimental MRR (E-MRR), experimental TWR (E-TWR), experimental SRR (E-SRR), and predicted MRR (P-MRR), predicted TWR (P-TWR), predicted SRR (P-SRR) generated by ANN-BWO shows effectiveness of AA7075-GR-B4C.

Multimodal 3D quantification of particle stimulated nucleation in industrially manufactured aluminium AA5182 sheet

Particle stimulated nucleation is a dominant recrystallisation mechanism observed in many industrially relevant aluminium alloys during thermomechanical processing. In this work, we quantify particle stimulated nucleation in 3D in an aluminium AA5182 alloy sheet cold-rolled to 75 % thickness reduction. Second phase particles and nuclei are mapped in the same sample volume by conventional laboratory absorption X-ray tomography and synchrotron X-ray Laue micro-diffraction. The large second phase particles are classified as Fe- and Mg-rich phases. It is found that84 % of the nuclei are particle stimulated and 40 % of the particles stimulate nucleation. The critical particle diameter is found to be 4μm. Deviatoric elastic strains are derived from micro-diffraction data and it is found that elastic strains are present in the recrystallised nuclei. The effects of the different particle types, particle clustering, particle size and aspect ratio as well as strain inheritance are discussed. This work provides a full 3D quantification of particle stimulated nucleation behaviour in AA5182 alloy sheet deformed to high strain.

Development of anti-corrosion, structural, and optoelectronic potential of Capsicum annuum-Doped AA6063 alloy for marine applications

The study explores the potential of incorporating pepper waste as a reinforcement material in aluminium AA6063 composites, with focussing on the morphological, mechanical, electrochemical, and optoelectric properties. Pepper wastes, including stalks and seeds, were carbonised, pulverized, and sieved to yield 75 μm particulates. These were mixed with molten AA6063 alloy via stir casting, with the pepper content ranging from 0% to 25% by weight. The composites were characterised using hardness testing, electrochemical evaluation, optoelectrical analysis, and morphological analysis. Hardness tests revealed that the 25% pepper-reinforced sample exhibited the highest hardness value of 37 HRB, a 31.7% increase over the control sample. Electrochemical evaluations showed significant improvements in corrosion resistance, with the corrosion potential (Ecorr) of the 25% pepper-reinforced sample reducing to −0.59 V and the corrosion rate decreasing to 7.69 mm/yr. Optoelectrical testing indicated enhanced conductivity in samples with higher pepper content, with the 25% reinforcement achieving a conductivity of 0.1979 (Ωm)⁻1. Morphological tests, such as SEM and XRD, revealed the uniform distribution of pepper particles and the occurrence of several phases that contribute to the composite's improved properties.

Hot Torsion Tests of AA6082 Alloy

Materials characterization and the knowledge of their elastic-plastic behavior are of fundamental importance for the design of industrial manufacturing processes. Nowadays, FEM simulation is the main tool used to optimize product quality and minimize scraps, and the numerical codes have evolved over the years to obtain accurate solutions with reduced computational times. Nevertheless, in order to perform reliable simulations, it is necessary to include accurate modeling of the material flow stress. Hot torsion is a powerful method for the characterization of the material flow stress because, tests can be carried out at constant speeds and temperatures, reaching large strain values, and thus getting over the limits of compression and tensile tests. In this paper the hot torsion characterization applied to AA6082 alloy is presented: tests were performed with equivalent strain rates of 0.01, 0.1, 1, and 10 s-1, in the temperature range from 440 to 550 °C (from 713.15 to 823.15 K). The results are presented in terms of equivalent stress vs equivalent strain. Finally, the material flow stress curve was predicted by the Hyperbolic sine model and Hensel-Spittel law, and the material parameters A, m1-9 are provided for the temperature expressed in °C and K.

Investigating the Tribological Behavior of Bioinspired Surfaces in Agro-waste and Alumina Reinforced AA6063 Matrix Composites

The tribological behavior of three bioinspired (BI) agro-waste ashes—bean pod ash (BPA), cassava peel ash (CPA), and coconut husk ash (CHA)—integrated as reinforcements in an alumina-reinforced AA6063 matrix hybrid and monolithic composite was investigated. Studies utilizing agro-wastes for bioinspired surfaces are limited despite these wastes posing significant environmental challenges. Consequently, there has been a growing effort to valorize these residues for sustainable engineering applications. This study uses a two-step stir-casting methodology to engineer bioinspired materials with lightweight properties, exceptional hardness, and wear-resistant characteristics. Microstructural investigations revealed a homogeneous distribution of natural and synthetic reinforcements within the AA6063 matrix. Lightweight AMCs were successfully fabricated, exhibiting densities ranging from 2.57 to 2.74 g/cm³ and hardness values between 81.28 and 107.47 BHN. The average surface roughness of these composites varied from 2.4 to 3.4 μm, with ANOVA tests confirming a statistically significant difference (p < 0.005). Wear rates and the coefficient of friction were observed to range from 2.52 x 10-3 to 5.50 x 10-3 mm³/m and 0.2476 to 0.5403, respectively. Reinforcing the AA6063 alloy with bioinspired agro-wastes significantly enhanced the hardness and tribological performance of the as-cast BI-AMCs. Notably, the wear rates and friction coefficients were significantly reduced, with the monolithic BI-AMCs demonstrating superior results. Furthermore, adding bioinspired agro-wastes, such as BPA, CPA, and CHA, improved the surface texture of AA6063 more effectively than Al2O3, leading to slightly smoother surfaces. These nuanced bioinspired tribological behaviors present opportunities for tailored load-bearing and aesthetic applications derived from agro-waste-based composites. This study advances our understanding of bioinspired tribological phenomena and paves the way for the development of innovative materials with diverse applications and enhanced performance.

ANN modeling and optimization of friction stir welding performance for AA6061 and AA5083 alloy joints

This research focused on the characteristics of the AA6061/AA5083 alloy joints which are fabricated by the friction stir welding (FSW) technique. The impact of FSW parameters such as tool tilt angle, pin depth, and tool geometry on the mechanical properties and fractographic characteristics were studied. Ultimate tensile strength (UTS), hardness (HBN), and specific wear rate (SWR) were examined for characterization while fractography analyses were done using scanning electron microscopy. Taguchi-Grey relational analysis (GRA) was employed to execute multicriteria optimization and recognize the best grouping of parameters. The optimized values attained from this analysis were 259.2 MPa for UTS, 94.9 HV for HBN, and 0.0819 m³/Nm for SWR. The analysis of variance (ANOVA) results derived from the GRA revealed that tool geometry exerted the most significant influence (39.79%) on output factors, followed by pin depth (24.90%) and tilt angle (24.26%). To enhance the predictive accuracy of the output responses, an artificial neural network (ANN) model was developed utilizing the Levenberg-Marquardt (LM) algorithm. The optimized ANN architecture, configured as (3–10–3), exhibited robust regression analysis outcomes, showcasing correlation coefficients ( R) of 0.99999, 0.99967, and 0.99994 for the training, validation, and test datasets. The overall R-value, computed at 0.99958, affirmed high conformity between experimental and predicted values.