Optimization of Tool Pin Geometry Parameters to Improve the Performance of Friction Stir Welding of AA1050

This study attempts to examine the performance of new pin geometry during friction stir welding for AA 1050 butt joints for a plate thickness of 4 mm. In this research, the impact of FSW on mechanical characteristics has been analyzed without making any alterations to the process parameters. This was achieved by employing nine distinct tool shapes developed using the Taguchi (OA) approach, which involved manipulating the rotational speed and feed. The four variable geometrical parameters that were considered in this study included pin length (mm), diameter of pin (mm), angle of pin (α°), and pin shape. Each of these parameters was evaluated at three levels to examine the outcomes, utilizing the (S/N) ratio method. Specifically, the statistical software MINITAB®18 was applied to find the optimum condition. The ultimate tensile strength (UTS) was assessed for all the experimental trials, followed by a statistical variance analysis (ANOVA). The confirmation test involved the completion of the welding process under optimal conditions. Additionally, statistical software, specifically the design of experiments, was applied to perform the ANOVA approach to finding the significant factors impacting the UTS. The most effective element combinations were predicted and validated. A micro hardness (HV) test was also performed to evaluate the mechanical properties of the welded joints.