Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Optimization of friction stir additive manufacturing (FSAM) process parameters to improve Its mechanical properties and performance

Document Type : Original Article

Authors
Ali Emami 1
Majid Elyasi 1
Mohammad Javad Mirnia 1
Maziar Ramezani 2
1 Faculty of Mechanical Engineering, Babol Noshirvani University of Technology, Babol, Iran
2 Faculty of Mechanical Engineering, Flinders University, Australia
10.22034/ijme.2026.549788.2134
Abstract
The Friction Stir Additive Manufacturing (FSAM) process is a solid-state method for layer-by-layer metal fabrication, in which metallic layers are joined using a rotating tool without complete melting, thereby avoiding defects associated with fusion-based methods such as porosity and solidification cracks. In this study, the optimization of FSAM parameters was investigated to improve the tensile strength of the joint between aluminum 1050 (lower sheet) and 3105 (upper sheet). Three key parameters tool rotational speed, traverse speed, and tool geometry were selected as influential variables. The experimental design was conducted based on the Taguchi method (L9), and data analysis was performed using the signal-to-noise (S/N) ratio in the “larger-is-better” mode. The results indicated that the optimal combination of parameters led to the maximum tensile strength of the specimens, and the effect of each parameter on joint quality was determined through main effects analysis. The maximum tensile stress observed was 164.11 MPa, and the experimental mean of the specimens was 151.14 ± 7.94 MPa. The analysis showed that traverse speed had the greatest influence on tensile strength, while rotational speed and tool geometry also played significant roles. This study demonstrates that optimal selection of FSAM parameters can effectively enhance the mechanical properties of fabricated components and provides scientific guidance for designing operational parameters.
Keywords
FSAM
Rotational Speed
Feed Rate,
Tool Geometry
Tensile Strength
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