Multi-Objective Optimization and Mechanical Performance Analysis of Friction Stir Welded Aluminum Pipes

Abstract

Conventional fusion welding of aluminum pipes often leads to defects such as root cracking, thermal distortion, and lack of proper fusion. To address these issues, a dedicated friction stirs welding (FSW) setup along with a specially designed tool was developed for joining aluminum pipes. In this study, the influence of key process parameters, including tool rotational speed, traverse speed, and axial force, on weld quality and mechanical performance was investigated. The welded joints were evaluated using tensile testing, micro-Vickers hardness measurements, and visual inspection techniques. The results show that both tool design and process parameters play a significant role in determining weld quality. With properly selected parameters, improved mechanical properties and better weld integrity can be achieved.