Failure evaluation on tailor made aerospace aluminum alloys via underwater friction stir welding employing predictive machine learning technologies

Employing tailor-made alloys with uneven thickness achieves light weighting, a critical issue for reducing emissions, leading to lower aircraft pollutants and fuel costs. The research utilizes advanced machine learning techniques such as Gaussian process regression (GPR), artificial neural networks (ANN) linear regression (LR), and support vector machines (SVM) to predict the ultimate tensile strength of underwater friction stir welding of AA6082-T6 and A2219-T83 tailor-made joints. The models have been evaluated with an assortment of kernel functions, including the polynomial kernel (PK), the radial basis function (RBF), and the Pearson VII universal kernel (PUK). To acquire experimental data, we used a Central Composite Design (CCD) technique, incorporating various factors in the process encompassing tool tilt angle (TA), rotating speed (RS), and welding speed (WS). The SVM radial basis function model (SRBP) had a maximum correlation coefficient of 0.9995 and a minimum root mean square error value (RMSE) of 0.5433 in the training set and 0.6271 in the test set. The ANN model predicted the UTS with an error margin of 0.21%, while the SRBP model showed a 0.52% error, and the LR model exhibited a significantly higher error of 7.73%. A peak tensile strength of 252.98 MPa was recorded in the S20 specimen, accounting for 85.61% of the base metal’s (AA6082 T6) strength. A reduced acute tearing ridge indicates petite, shallow dimples due to the inherent cooling. Through the analysis of metrics and residuals, high accuracy rates were observed when employing the ANN and SRBP models to predict mechanical traits.