Optimization of process parameters of friction stir welded joint of dissimilar aluminum alloy AA5083 and AA6082 (original) (raw)

In this investigation central composite design (CCD) technique and mathematical model was developed by response surface methodology with three parameters, four levels and 20 runs, was used to develop the relationship between the FSW parameters (rotational speed, traverse speed, and tilt angle) and the responses (tensile strength, % Elongation, micro-hardness and residual stress) of dissimilar aluminum alloys AA5083 and AA6082 were established. The maximum tensile strength (214 MPa) was found at tool rotation speed 1300 rpm, traverse speed 45 mm/min with tilt angle 10 . The maximum micro-hardness (86 HV) was found at tool rotation speed 1300 rpm, traverse speed 45 mm/min with tilt angle 10 . The minimum tensile strength (161 MPa) was observed at tool rotation speed 1000 rpm, traverse speed 30 mm/min with tilt angle 20 . In addition, a numerical model and empirical relationship was developed by design expert software between processing parameters (tool rotation speed, traverse speed, and tilt angle) and response surface parameters (tensile strength, percentage elongation and microhardness at nugget zone) and the optimized value of tensile strength, % elongation, microhardness, and residual stress were observed as 187.6 MPa, 19.93, 78.39 HV and 22.02 MPa respectively.