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Experimental Modeling and Multi-Response Optimization in Friction Stir Welding Process Parameters of AA2024-T3 Using Response Surface Methodology and Desirability Approach

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Abstract

This work deals with the regression models and multi-objective optimization method of the ultimate tensile strength, percentage of elongation, and average arithmetic surface roughness of butt friction stir welded AA2024-T3 aluminum alloy. Machining experiments were carried out according to the face centered central composite design of the response surface methodology. The effect of friction stir welding process parameters such as rotation speed, welding speed, and tool shoulder diameter on responses was investigated. Adequacies of the models are checked by the analysis of variance. The optimization of multiple responses was performed using the desirability analysis to achieve the higher ultimate tensile strength, maximum percentage of elongation, and minimum arithmetic surface roughness. From this investigation, it is found that the joints fabricated with the tool rotational speed of 752 rpm, welding speed of 100 mm/min, and tool shoulder diameter of 12.5 mm yield the maximum ultimate tensile strength and percentage of elongation, and minimum arithmetic surface roughness of 379.69 MPa, 10.22% MPa, and 6.66 HV, respectively. The effects of process parameters on the microhardness of welded zone were studied. The macrostructure, microstructure, and residual stress characterization of joints are examined.

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Acknowledgements

We would like to thank Dr. Anis Hor of the department of mechanics, structures and materials (DMSM) of the High Institute of Aeronautics and Space (Toulouse), France, for all their cooperation and contribution to research work. My sincerest thanks are also extended to the technicians of this department for their help in doing the residual stresses measurement.

Funding

The authors did not receive support from any organization for the submitted work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Engineering School of Bizerte, University of Carthage, Menzel Abderrahman University Campus, Bizerte, Tunisia

    K. Boulahem & S. Shiri

  2. Laboratory of Applied Mechanics and Engineering, National Engineering School of Tunis, University of Tunis El Manar, 1002, Tunis, Tunisia

    K. Boulahem, S. B. Salem, S. Shiri & J. Bessrour

  3. Preparatory Institute for Engineering Studies of Nabeul, Mrezka University Campus, 8000, Nabeul, Tunisia

    S. B. Salem

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Contributions

Khaled Boulahem: Conceptualization, Supervision, Methodology, Funding acquisition,

Writing- original draft preparation.

Sahbi Ben Salem: Conceptualization, Methodology, Validation.

Seddik Shiri: Investigation, Formal analysis.

Jamel Bessrour: Review & Editing.

All the authors read and approved the manuscript.

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Correspondence to K. Boulahem.

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Boulahem, K., Salem, S.B., Shiri, S. et al. Experimental Modeling and Multi-Response Optimization in Friction Stir Welding Process Parameters of AA2024-T3 Using Response Surface Methodology and Desirability Approach. Exp Tech (2024). https://doi.org/10.1007/s40799-023-00691-9

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