The present investigation is to optimize the welding parameters designed for friction stir welding (FSW) of aluminium magnesium alloy (AA5052). The authentic configuration of automated linear friction stir welding machine used to weld the AA5052. The experiments were conducted by selecting the different welding process parameters like tool rotation speed (rpm), traverse speed (mm/min), and tool pin profiles. The pin profile made with ceramic tool type (high carbon high chromium). Taguchi based desirability function analysis engaged in establishing the optimal process parameters with multi-objective function in order to maximize the tensile strength and the nugget hardness. The welding parameter of optimum level was attained by the highest composite desirability value. An optimal level of welding parameters acquired the tool rotation speed at 1200 rpm, traverse speed at 30 mm/min, and the pentagonal tool pin profile. Further, ANOVA (analysis of variance) implemented to intimate the major impact of welding parameters on the output responses (tensile strength and nugget hardness). An outcome perceived that the tool pin profiles and tool rotational speed are the important consequence factors to manipulate the mixed output responses. Contour plots and mean effect show that the interaction of parameters of welding on the required output response.

Keywords: DFA, HCHCr tool, FSW, Tensile, Microhardness, Microstructure