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In this study, fuzzy logic neural networks were employed to optimize the friction stir welding (FSW) process parameters in the joining of copper plates. The FSW parameters were considered as the input variables, for which micro-hardness, nano-hardness, and yield strength of the joints were the responses. The micro-hardness and nano-hardness were measured by Vickers hardness and nanoindentation tests, respectively. The microstructure and substructure of the joints were evaluated by optical, scanning electron, and orientation imaging microscopes. The optimum process parameters through which the maximum strength was achieved were the tool rotational rate of 560 rpm, tool traverse speed of 175 mm/min, and tool axial force of 2.27 kN. The low heat input joints, owing to the finer grain sizes, high density of dislocations, and larger Taylor factors, indicated greater strength relative to the high input joints. Microstructure characterization revealed that dominant strengthening mechanisms of the joints were dislocation density, texture effect, and grain boundary hardening.

Unraveling the Relationship between Microstructure and Mechanical Properties of Friction Stir-Welded Copper Joints by Fuzzy Logic Neural Networks