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<p>Friction stir welding (FSW) is a solid-state joining technique widely employed for aluminum alloys due to its ability to produce high-quality joints without melting the base material. However, optimizing FSW parameters to achieve superior mechanical performance, particularly for heat-treatable alloys such as AA2017-T4, remains a challenge due to the complex interactions between process variables. This study addresses this gap by optimizing the FSW parameters for AA2017-T4 using the L16 Taguchi design method. Modeling and experimental datasets were thoroughly analyzed to evaluate the ultimate tensile strength (UTS) of the weld joints. The primary objective was to determine the optimal combination of process parameters to maximize UTS. Results revealed that UTS is most sensitive to tool rotational speed compared to other parameters. The optimized regression model predicted a maximum joint efficiency of 95.29%, representing a clear improvement over values previously reported in the literature for this alloy. This efficiency was obtained using a tool rotational speed of 1200 rpm, welding speed of 32 mm/min, tool tilt angle of 1.5°, cylindrical pin profile, and a penetration depth of 0.6 mm. Fractographic analysis further demonstrated that variations in these parameters notably affect material mixing, weld strength, and fracture behavior. Distinct fracture surface morphologies, ranging from ductile dimples to quasi-brittle features, were correlated with specific parameter combinations, thereby confirming the link between process optimization and enhanced joint performance.</p>

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Optimization approach using L16 Taguchi design to improve FSW parameters for AA2017-T4 weld joints

  • 期刊论文

  • 发表日期：

    2025年6月3日

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  • Houssem Eddine Lakache,
  • Adel Belattar,
  • Abdelghani May,
  • Chourouk Merazga,
  • Toufik Chergui,
  • Habib Lahmar,
  • Abdelghani Mokdad

摘要

Friction stir welding (FSW) is a solid-state joining technique widely employed for aluminum alloys due to its ability to produce high-quality joints without melting the base material. However, optimizing FSW parameters to achieve superior mechanical performance, particularly for heat-treatable alloys such as AA2017-T4, remains a challenge due to the complex interactions between process variables. This study addresses this gap by optimizing the FSW parameters for AA2017-T4 using the L16 Taguchi design method. Modeling and experimental datasets were thoroughly analyzed to evaluate the ultimate tensile strength (UTS) of the weld joints. The primary objective was to determine the optimal combination of process parameters to maximize UTS. Results revealed that UTS is most sensitive to tool rotational speed compared to other parameters. The optimized regression model predicted a maximum joint efficiency of 95.29%, representing a clear improvement over values previously reported in the literature for this alloy. This efficiency was obtained using a tool rotational speed of 1200 rpm, welding speed of 32 mm/min, tool tilt angle of 1.5°, cylindrical pin profile, and a penetration depth of 0.6 mm. Fractographic analysis further demonstrated that variations in these parameters notably affect material mixing, weld strength, and fracture behavior. Distinct fracture surface morphologies, ranging from ductile dimples to quasi-brittle features, were correlated with specific parameter combinations, thereby confirming the link between process optimization and enhanced joint performance.