Friction stir welding (FSW) is a solid-state welding process commonly used to join similar and dissimilar aluminum alloys. This study aims to investigate multi-criteria decision-making, multi-objective optimization, Taguchi’s L9 design of experiments, and the technique for order preference by similarity to the ideal solution (TOPSIS) to evaluate the effects of various FSW parameters specifically, welding speed, feed, and axial load on the mechanical properties of AA5754 aluminum alloy. Following the enhancement of the welding parameters, an analysis of variance (ANOVA) was performed to identify the most influential parameter in the FSW process. The findings indicated that tensile strength, impact strength, and microhardness were predominantly affected by welding speed (94.82%), feed (3.12%), and axial load (1.32%), respectively. With a hexagonal tool and optimal process parameters of feed (20 mm/min), axial load (7 kN), and speed (1200 rpm), the joint obtained the maximum microhardness (81 HV), impact strength (3.01 J/mm2), and tensile strength (163.89 MPa). The microstructure and X-ray diffraction analyses indicated that the crystals were tiny, with higher dislocations in the stir zone, indicating improved mechanical properties. In the FSW joint, dimples and voids were observed on the tensile and impact fracture surfaces. Finally, the ballistic properties of the optimized AA5754 FSW joint were determined. An asymmetric V-shaped deformation profile was observed around the impact point, with the highest deformation at the center. An increase in impact velocity from 134 to 187.6 m/s did not result in significant differences in the deformation of the FSW joint. The fracture surfaces of ballistic-tested friction stir welded joints exhibited shear regions and localized bands.
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