Application of Taguchi optimization technique in determining aluminum to brass friction stir welding parameters

Highlights: • Lap joints between AA5083 and CuZn34 were successfully produced by FSW. • Taguchi optimization technique was used to find the optimum parameters in FSW. • To control the effectiveness of Taguchi method, a confirmation test was conducted. • Rotational speed plays a vital role and contributes 40% to the overall contribution. - Abstract: In this research Al–Mg and CuZn34 alloys were lap joined using friction stir welding during which the aluminum alloy sheet was placed on the CuZn34 and the process parameters were optimized using Taguchi L9 orthogonal design of experiments. The rotational speed, tool tilt angle and traverse speed were the parameters taken into consideration. The optimum process parameters were determined with reference to tensile shear strength of the joint. The predicted optimal value of tensile strength was confirmed by conducting the confirmation run using optimum parameters. Analysis of variance showed that rotational speed is the most dominant factor in deciding the joint soundness. Optical microscopy and scanning electron microscopy (SEM) analysis were used to probe the microstructures and chemical compositions