Joint characteristics and process parameters optimization on friction stir welding of AA 2024-T6 and AA 5083-H111 aluminium alloys
Sakthivel Sundaram, Mohan Kumarasamy
Abstract
Friction stir welding (FSW) is a recent method for welding in a solid-state environments. The FSW parameters, namely pin rotation speed, welding speed, axial force and tool tilt angle affect weld joint microstructure and tensile strength. The study optimizes process settings to enhance mechanical properties and uses Response surface methodology (RSM) to predict the ultimate tensile strength (UTS) of FS-welded AA 2024-T6 and AA 5083-H111.These parameters must be understood in order to get optimal mechanical qualities in manufacturing. The created model predicted tensile strength within 5 % of experimental data, helping optimize process parameters for FSW joints. Tool tilt angle affects heat, material flow, defect generation, welding force, and friction stir weld joint quality.