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<p>This study presents a multi-objective optimization of submerged friction stir welding (SFSW) parameters for Al-Cu-Mg alloy using the Taguchi L16 experimental design. The influence of five process variables including tool rotational speed, welding speed, pin profile, environmental temperature, and immersion liquid type on the ultimate tensile strength (UTS) and bending resistance of welded joints was systematically investigated. The results indicate that tool rotational speed is the most critical factor affecting both UTS and bending performance, followed by welding speed and pin profile. Environmental temperature and immersion liquid type showed negligible effects. Regression models developed for UTS and bending resistance at both the top and bottom surfaces of the SFSW joints demonstrated strong predictive accuracy when compared to experimental data. The optimized parameters led to significant improvements in joint efficiencies, reaching 88.21% for UTS, 96.99% for bending resistance at the top face, and 73.24% at the bottom face relative to the base metal. Fractographic analysis revealed a ductile fracture mode characterized by a rough and cupular morphology on the upper fracture surface, whereas the lower surface exhibited a chip-like morphology indicative of localized brittle fracture.</p>

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Multi-objective optimization of submerged friction stir welding parameters for Al-Cu-Mg alloy

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • Houssem Eddine Lakache,
  • Abdelghani May,
  • Adel Belattar,
  • Ahmed Assim Berkani,
  • Islam Hamici

摘要

This study presents a multi-objective optimization of submerged friction stir welding (SFSW) parameters for Al-Cu-Mg alloy using the Taguchi L16 experimental design. The influence of five process variables including tool rotational speed, welding speed, pin profile, environmental temperature, and immersion liquid type on the ultimate tensile strength (UTS) and bending resistance of welded joints was systematically investigated. The results indicate that tool rotational speed is the most critical factor affecting both UTS and bending performance, followed by welding speed and pin profile. Environmental temperature and immersion liquid type showed negligible effects. Regression models developed for UTS and bending resistance at both the top and bottom surfaces of the SFSW joints demonstrated strong predictive accuracy when compared to experimental data. The optimized parameters led to significant improvements in joint efficiencies, reaching 88.21% for UTS, 96.99% for bending resistance at the top face, and 73.24% at the bottom face relative to the base metal. Fractographic analysis revealed a ductile fracture mode characterized by a rough and cupular morphology on the upper fracture surface, whereas the lower surface exhibited a chip-like morphology indicative of localized brittle fracture.