Parametric optimization of friction stir welding of ZE42 using NSGA-II

The main objectives of the proposed work are to make sound welded joints, optimize the parameters involved in welding, perform the metallurgical characterization of various weld zones, and discover the new option of producing sound welded joints among the ZE42 and the different alloys of magnesium. As two dissimilar materials are needed to be joined, it is essential to analyze and recognize the flow of material throughout the process of friction stir welding (FSW). It is also significant to know the corrosion characteristics of the welded joint, mainly at the stir zone where two dissimilar magnesium alloys are combined. The FSW of Mg-Cu-Al alloys, namely ZE42 is considered impossible, mostly due to the presence of solidification cracking. The fusion of dissimilar ZE42 magnesium alloys with the use of any fusion welding method is also not possible, because of the occurrence of 6.5% Cu and 74.5% Mg respectively. This work focused mainly on the modeling and the optimization of the parameters of FSW process of ZE42 alloy with the consideration of Hardness and Tensile Strength using NSGA II. The modeling of the proposed technique is done using the regression analysis. Confirmatory experiments have been conducted to validate the optimum conditions.