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<p>This study investigates the combined influence of tool pin geometry, shoulder-to-pin diameter ratio (D/d), spindle speed, and welding speed on material flow, temperature distribution, and surface quality during friction stir welding (FSW) of AA3103 aluminium alloy. A Taguchi L9 orthogonal array was employed to minimize experimental trials while identifying the most significant process factors. Twenty-seven welds were fabricated using three distinct tool pin profiles square, circular, and triangular and evaluated through infrared thermography and surface profilometry. The results revealed that higher spindle speeds coupled with lower welding speeds enhanced material plasticization, reduced surface roughness, and improved heat uniformity across the weld zone. Among all configurations, the circular pin produced the most stable and defect-free welds, while square pins generated higher frictional heat but exhibited greater roughness variations. The optimum parameter combination of 710 RPM spindle speed, 20&#xa0;mm/min traverse speed, and D/d = 4 achieved the lowest surface roughness (Ra ≈ 1.37&#xa0;µm). Statistical and thermal correlation analyses confirmed that spindle speed was the dominant parameter influencing both heat input and surface morphology. The study establishes a novel thermo-statistical optimization framework for AA3103, integrating Taguchi-based design with infrared thermographic validation. The findings provide practical guidelines for achieving superior weld quality in lightweight aluminium applications across automotive and aerospace sectors.</p>

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Experimental and Thermo-Statistical Optimization of Tool Geometry and Process Parameters in Friction Stir Welding of AA3103 Aluminium Alloy

  • 期刊论文

  • 发表日期：

    2026年4月18日

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  • Ganesh Jagannath Pagar,
  • Gajanan N. Shelke

摘要

This study investigates the combined influence of tool pin geometry, shoulder-to-pin diameter ratio (D/d), spindle speed, and welding speed on material flow, temperature distribution, and surface quality during friction stir welding (FSW) of AA3103 aluminium alloy. A Taguchi L9 orthogonal array was employed to minimize experimental trials while identifying the most significant process factors. Twenty-seven welds were fabricated using three distinct tool pin profiles square, circular, and triangular and evaluated through infrared thermography and surface profilometry. The results revealed that higher spindle speeds coupled with lower welding speeds enhanced material plasticization, reduced surface roughness, and improved heat uniformity across the weld zone. Among all configurations, the circular pin produced the most stable and defect-free welds, while square pins generated higher frictional heat but exhibited greater roughness variations. The optimum parameter combination of 710 RPM spindle speed, 20 mm/min traverse speed, and D/d = 4 achieved the lowest surface roughness (Ra ≈ 1.37 µm). Statistical and thermal correlation analyses confirmed that spindle speed was the dominant parameter influencing both heat input and surface morphology. The study establishes a novel thermo-statistical optimization framework for AA3103, integrating Taguchi-based design with infrared thermographic validation. The findings provide practical guidelines for achieving superior weld quality in lightweight aluminium applications across automotive and aerospace sectors.