The axial down force, the starting temper of the work piece, the material of the tool and its hardness, the material and thickness of the backing plate, the kind of cooling system, and the clamping fixture all have an impact on the FSW process. A fundamental prerequisite for obtaining effectively, defect-free friction stir welded joints is the selection of friction stir welding settings that generate appropriate mechanical, microstructural, fatigue, and corrosion characteristics. It is not an easier task to set the process parameters at the optimal values. This cannot be done using the trial and error method. Developed a methodology to identify the optimal process parameters. This present work discusses the detailed procedure to find the optimal process parameters which in turn the entire process can be automated. For this study, we will use this technique to improve the mechanical properties and microstructure of an aluminium alloy casting's friction stir process, investigate the variable in the stirring that affects the structure of the microstructure and mechanical properties of the area to stir zone, and improve the processes used to improve the mechanical properties as well as terms of research and to extend the results to the industry for future developments.

Tool Geometry, Optimal Values, Stir Zone, Future Developments