A growing number of industries are utilizing friction stir welding (FSW), which
has shown promise for joining different materials. In this study, the impacts of
rotation speed and tool pin shape are examined, as well as the FSW zone
generation in the magnesium alloy AZ31. The physical attributes of rotation
speed, feed rate, pin profile shape, and the mechanical properties of the AZ31
magnesium alloy hardness, impact energy, and tensile strength are examined in
this research to determine the properties of FSW. Under optimal conditions,
taper-threaded tool pins, 40 mm/min welding speed, and 1000 rpm rotation speed
achieved maximal micro-hardness. The FSW tool creates heat at 1000 rpm,
improving the softened metal’s mechanical properties. Thus, the metal content in
the stir zone was uniform. Some process variables impacted the response surface
methodology (RSM) parametric design and subsequent optimization procedure.
According to the analysis, the tool’s rotational speed was the key progression
variable with the most statistical influence on metal characteristics.
Nonetheless, tool pin design and welding speed are other variables that
significantly influence mechanical properties.