Evaluation of process parameter of friction stir processing of AA2024-T351 Alloy using RSM and GRA

A fundamental method for changing the characteristics of metals through localised severe plastic deformation is friction stir processing (FSP), which is both straightforward and efficient. Because of its high strength-to-mass ratio and resilience to fatigue, aluminium alloy 2024 is commonly utilised. The experiments were designed utilising the Box–Behnken method and the process parameters’ chosen range values. In this research, the impact of FSP process variables on the tensile, surface roughness, and hardness properties of AA2024 will be examined. These parameters include tool rotation speed, welding speed, and axial load. The base sample tensile strength, surface roughness and microhardness values were 325 MPa, 0.5125 μm, and 120 HV. The optimised sample’s maximum tensile strength, minimum surface roughness, and maximum microhardness values were 420 MPa, 0.4 μm, and 144 HV. The grey relational analysis (GRA) determines the ideal combination of process parameter values for the best values in all responses. XRD was used to assess residual stress, dislocation density and micro-strain. The optimal process parameters have been obtained at a rotational speed of 1000 rpm, traverse speed of 45 mm/min, and axial load of 10.25 kN.