Optimisation of FSP parameters in cast magnesium alloy using hybrid GRA methodology

The current investigation utilised the grey relational analysis (GRA)-Taguchi-principal component analysis (PCA) methodology to discover the optimal friction stir processing (FSP) parameters for the treatment of cast Mg-2%Al-1%Si alloy derived from AS series magnesium alloys. The input parameters of the rotation rate, traverse speed, and shoulder size were chosen based on the L9 Taguchi design, and the maximum tensile strength, Ductility or % extension, and microhardness were the multiple responses. By using an optimisation strategy, these responses were combined into a single response called grey relational grade (GRG). The optimised combination of process parameters was determined as 800 rpm rotation rate, 50 mm/min traverse speed and 20 mm shoulder size, which produced the largest GRG value. The ANOVA analysis revealed that the rotation rate parameter exerted a significant influence on the process. Furthermore, the predicted results were verified through a confirmation experiment and were found to be consistent with the experimental outcomes.