Multi-objective Optimization of Continuous Drive Friction Welding Process Parameters Using Response Surface Methodology with Intelligent Optimization Algorithm

The optimum friction welding (FW) parameters of duplex stainless steel (DSS) UNS S32205 joint was determined. The experiment was carried out as the central composite array of 30 experiments. The selected input parameters were friction pressure (F), upset pressure (U), speed (S) and burn-off length (B), and responses were hardness and ultimate tensile strength. To achieve the quality of the welded joint, the ultimate tensile strength and hardness were maximized, and response surface methodology (RSM) was applied to create separate regression equations of tensile strength and hardness. Intelligent optimization technique such as genetic algorithm was used to predict the Pareto optimal solutions. Depending upon the application, preferred suitable welding parameters were selected. It was inferred that the changing hardness and tensile strength of the friction welded joint influenced the upset pressure, friction pressure and speed of rotation.