Optimization of Al-Cu Friction Stir Welding Parameters Through RSM and BOA

In the automobile industry, the use of aluminum has increased with the need for lightweight and robust structures. In situations where an interface of aluminum with other materials like copper and steel is required, solid state welding process such as Friction Stir Welding (FSW) is very useful. In this research, an aluminum to copper dissimilar metal FSW welded joint is studied. The welding parameters required for joining Aluminum and Copper are optimized through Response Surface Method (RSM) and a novel optimization technique called Butterfly Optimization Algorithm (BOA). In the first phase, the critical friction stir welding parameters are tabulated. A series of welding simulations are carried out to determine temperature profile achieved through these parameters. The design of experiment approach is used to run regression analysis through response surface method. In the second phase, Butterfly Optimization Algorithm is applied to optimize the process parameters. The weld parameters optimized through BOA give an improved temperature profile to create a sound weld. Weld samples are prepared to validate the results. The tool rotational speed is found to be the major contributor in defining the temperature profile of base plates.