Articles
  • Optimization of Friction Stir Welding Parameters for AA5052-AA2014 Joints Using Critic and Marcos Methods: Evaluation of Mechanical Properties and Tool Pin Profiles

  • Satishkumar P.a,*, Abdulrahman Khamajb, Abdulelah M. Alic, Rajasekaran Saminathand, Madhuri S. Bhagate, Sumant. K. Kulkarnif and Dhananjay R. Dolasg

  • aDepartment of Mechanical Engineering, Rathinam technical campus, Coimbatore, Tamilnadu, India
    bIndustrial Engineering Department, College of Engineering and Computer Science, Jazan University, Saudi Arabia
    cIndustrial Engineering Department, College of Engineering and Computer Science, Jazan University, Saudi Arabia
    dMechanical Engineering Department, College of Engineering and Computer Science, Jazan University, Saudi Arabia
    eAssistant Professor, Department of Civil Engineering, Yeshwantrao Chavan College of Engineering, Nagpur
    fSchool of Civil Engineering, REVA University, Bengaluru, Karnataka 560064, India
    gAssociate professor in Mechanical Engineering, Jawaharlal Nehru Engineering College, MGM University Aurangabad, Maharashtra, India

  • This article is an open access article distributed under the terms of the Creative Commons Attribution Non-Commercial License (http://creativecommons.org/licenses/by-nc/4.0) which permits unrestricted non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

Friction stir welding (FSW) is an innovative technique for joining both similar and dissimilar aluminum materials, extensively utilized in the automotive and aerospace sectors to mitigate problems like as porosity, hot cracking, and elemental loss related to fusion welding methods. This study investigates the amalgamation of two distinct materials, AA5052 and AA2014 and evaluates their mechanical properties concerning the influence of FSW process variables, such as welding speed (WS), tool rotational speed (TRS), and axial load (AL), on the integrity of the weld nugget zone formation. The critical functions of various tool pin profiles are also highlighted. The selection criteria are determined by the evaluated mechanical parameters, which encompass yield strength (YS), ultimate tensile strength (UTS), percentage of elongation, and hardness (HV). The CRITIC (criteria importance through intercriteria correlation) technique was employed to obtain the significance of criteria for performance assessment. The application of MARCOS (Measurement of Alternatives and Ranking according to Compromise Solution) for ranking assessment indicates that the sixteenth samples exhibit the most advantageous mechanical features. The findings demonstrate that defect-free weld joints are attained at a WS of 16 mm/min, a TRS of 1600 rpm, and an AL of 8 N using a hexagonal pin profile, resulting in a UTS of 227 MPa, an YS of 215 MPa, a percentage of elongation of 8.5, and a hardness of 96 HV. The confirmation of the ranking through various decision-making instruments illustrates the dependability and efficiency of the suggested methodology.


Keywords: Aluminum alloys, Mechanical properties, Friction stir welding, CRITIC, MARCOS.

This Article

  • 2025; 26(6): 916-932

    Published on Dec 31, 2025

  • 10.36410/jcpr.2025.26.6.916
  • Received on Jun 12, 2025
  • Revised on Jul 24, 2025
  • Accepted on Aug 25, 2025

Correspondence to

  • Satishkumar P.

  • Department of Mechanical Engineering, Rathinam technical campus, Coimbatore, Tamilnadu, India
    Tel : 9791927002

  • E-mail: sp.sathishkumar10@gmail.com