Application of response surface methodology for optimizing friction stir welding parameters of AA6082-T6 aluminium alloy
Friction stir welding (FSW) has emerged as a primary fabrication technique for joining aluminum alloys, owing to its capability to produce defect-free, high-strength welds. The mechanical properties of FSW joints, such as ultimate tensile strength (UTS) and hardness (HV), are strongly influenced by...
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| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425017399 |
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| Summary: | Friction stir welding (FSW) has emerged as a primary fabrication technique for joining aluminum alloys, owing to its capability to produce defect-free, high-strength welds. The mechanical properties of FSW joints, such as ultimate tensile strength (UTS) and hardness (HV), are strongly influenced by key process parameters, including rotational speed (A), feed rate (B), tool tilt.(C) angle, plunge depth (D), and tool pin profile (E). This study employed Response Surface Methodology (RSM) to develop mathematical models for predicting these mechanical properties in friction stir-welded AA6082-T6 joints, based on the five factors at varying levels of optimal design. The analysis of variance (ANOVA) revealed that for UTS, factors such as rotational speed (A), plunge depth (D), and their interaction (AD) were most significant affecting the response, while for hardness, feed rate (B) and the interaction between the feed rate and the tilt angle (BC) were found to be the most influential affecting the response. These findings highlight the importance of optimizing these parameters to achieve the desired mechanical properties. The study also identified optimal parameter combinations that resulted in 79.6 % of the UTS and 82.8 % of the HV relative to the parent material. Three validation tests confirmed the accuracy of the regression models within a 95 % confidence level. The results from these tests further supported the strong correlation between the predicted and experimental values. This research enhances the understanding of FSW for aluminum alloys, offering valuable insights into the process parameters and their impact on mechanical properties. |
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| ISSN: | 2238-7854 |