Taguchi analysis of friction stir welded 5754 H111 aluminum alloy with 7075 T651 interlayer material
Year: 2026
Type: article
Abstract: The aim of this research is to improve the ultimate tensile strength (UTS) of welded AA5754-H111 aluminium alloy joints incorporating a 7075-T651 interlayer by optimizing the Friction Stir Welding (FSW) process parameters. The investigation employs the Taguchi approach to examine the effects of three key parameters: interlayer thickness (0.8, 1.0, 1.2 mm), welding speed (30, 40, 50 mm min −1 ), and tool rotational speed (750, 850, 950 rpm). According to the ANOVA results, the most influential parameter is tool rotational speed (F-value: 329.59, p = 0.000), followed by welding speed (F-value: 26.52) and interlayer thickness (F-value: 19.05). The optimal parameter combination—950 rpm tool rotational speed, 40 mm min −1 welding speed, and 0.8 mm interlayer thickness—achieved a tensile strength of 185.96 MPa, which is close to the experimental value of 185 MPa, with an error of only 0.96 MPa (0.52%). With an R 2 value of 98.68%, the residual analysis and surface plots confirmed the accuracy and reliability of the regression model. This study provides valuable insights into optimizing mechanical properties in interlayer-assisted FSW joints using statistical design techniques.
Source: Materials Research Express
Authors: Suresh Raj L, Manimaran G
Institution: Saveetha University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,000
OpenAlex ID: W7118278792