ORIGINAL RESEARCH article
Front. Mech. Eng.
Sec. Digital Manufacturing
Volume 11 - 2025 | doi: 10.3389/fmech.2025.1412251
Acoustic Emission Approach to Optimize Friction Stir Additive Manufacturing Process for Magnesium Alloy ZE41
Provisionally accepted
- 1SSN College of Engineering, Kalavakkam, India
- 2VSB-Technical University of Ostrava, Ostrava, Moravian-Silesian Region, Czechia
- 3Vel Tech Rangarajan Dr.Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
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Magnesium alloy ZE41 is highly regarded in industry due to its exceptional properties, including high strength, corrosion resistance, and lightweight characteristics. Friction stir additive manufacturing (FSAM) emerges as a promising solution to overcome challenges associated with conventional welding of magnesium alloy ZE41. Tool overrun, representing the distance traveled by the tool beyond the joint interface during FSAM, significantly impacts joint integrity and performance. There remains a research gap in FSAM, particularly concerning magnesium ZE41 alloy, where simultaneous consideration of output mechanical process parameters and acoustic signal features is lacking. This complex problem requires a dedicated decision support system (DSS). Therefore, the presented work aims to optimize the Friction Stir Additive Manufacturing Process for Magnesium Alloy ZE41 through the proposition of a dedicated DSS. In the proposed DSS, the linguistic evaluations from the experts regarding the output process parameters have been modeled through T-spherical fuzzy sets and the rankings of the various experiments have been deduced through the TODIM approach. To evaluate the impact of process parameters, three transverse speeds (20, 40, and 60 mm/min), two rotational speeds (500 and 1200 rpm), and two tool overruns (0.5d and 1d) were systematically varied. The study assessed process outcomes such as tensile strength, % elongation at break, Brinell hardness, and acoustic emission characteristics including peak amplitude, absolute energy and centroid frequency. The proposed approach yielded consistent ranking results, wherein experiment with transverse speed of 40 mm/min, rotational speed of 500 rpm and tool overrun of 1d has been revealed to be the best performing amongst the considered experiments. Despite changes in weights and attenuation factor, the ranking order remained consistent.
Keywords: Friction stir additive manufacturing, magnesium alloy ZE41, Additive manufacturing, TODIM, acoustic emission
Received: 04 Apr 2024; Accepted: 22 May 2025.
Copyright: © 2025 Zindani, K, A, Cep and K. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
* Correspondence: Divya Zindani, SSN College of Engineering, Kalavakkam, India
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