Optimizing Friction Stir Welding via Statistical Design of Tool Geometry and Process Parameters

This article considers optimization procedures for friction stir welding (FSW) in 5083-H321 aluminum alloy, via control of weld process parameters and tool design modifications. It demonstrates the potential utility of the "force footprint" (FF) diagram in providing a real-time graphical user interface (GUI) for process optimization of FSW. Multiple force, torque, and temperature responses were recorded during FS welding using 24 different tool pin geometries, and these data were statistically analyzed to determine the relative influence of a number of combinations of important process and tool geometry parameters on tensile strength. Desirability profile charts are presented, which show the influence of seven key combinations of weld process variables on tensile strength. The model developed in this study allows the weld tensile strength to be predicted for other combinations of tool geometry and process parameters to fall within an average error of 13%. General guidelines for tool profile selection and the likelihood of influencing weld tensile strength are also provided.