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Friction stir welding (FSW) is a well-established welding technique, which allows joining abutting surfaces by generating heating through a rotating and translating tool specifically shaped. Differently from the conventional techniques, continuous welding processes can be executed by FSW, thus supporting the economy of scales objectives. This paper deals with the selection of the optimal process parameters for the FSW of the AA6082 aluminum alloy. Three welding parameters, namely tool plunging, rotational speed and welding speed, have been handled as independent variables for developing two mathematical models by means of a non-linear regression-based approach, with the aim of predicting both ultimate tensile strength and ultimate elongation of the welded joints. A set of additional experimental tests has been used to validate the mentioned metamodels and finally three different metaheuristic algorithms have been implemented for selecting the best process parameters able to maximize the aforementioned mechanical properties. A comparison analysis based on further experimental tests confirmed the accuracy of the predicting metamodels and the quality of solutions yielded by the proposed optimization approaches.

Experimental Analysis and Optimization to Maximize Ultimate Tensile Strength and Ultimate Elongation of Friction Stir Welded AA6082 Aluminum Alloy