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The present manuscript focuses on developing a mathematical model to predict the intergranular corrosion rate of friction stir welded AA5086 H32 aluminium alloy joints. Six factors-Five levels central composite design matrix, having 52 experiments, is used for design of experiments. The developed model is used to examine the impact of studied process parameters i.e. rotational speed, welding speed, tool shoulder diameter, tool hardness, tilt angle , and pin profile on intergranular corrosion rate of the welded joints. Response surface methodology is used to optimize the process parameters for minimizing the susceptibility to intergranular corrosion attack. The optimum combination of studied parameters, to have minimum corrosion rate i.e. 3.2 mg/cm2, is obtained as 1296 rpm rotational speed, 79.4 mm/min welding speed, 14.9 mm tool shoulder diameter, 47.4 HRC tool hardness, 2.380 tilt angle, and square pin profile.

Modeling and optimization of friction stir welding parameters in joining 5086 H32 aluminium alloy.