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ABSTRACT
The novelty of the present work is the investigation of friction stir spot welding between AA2024 and AA7075 aluminum plates performed by Box-Behnken technique of response surface methodology. The chemical composition of the aluminum alloys is confirmed using XRD analysis. The process parameters of the FSSW process are analyzed to find the significant parameter that influences the output responses; it was revealed that the Tool Rotation Speed (TRS) was the influencing parameter. Furthermore, the most influenced tensile and hardness analysis of FSS Welded joint are identified by empirical analysis and it was found that the Tensile Shear force (Ts) was the improved property due to optimized FSSW process. Desirability approach was used to predict the optimal Ts value. The optimized process parameters are 2168.813 rpm of TRS, 3.32 mm depth of plunge and 46.98s dwell time. The computed Ts values for the present work investigation were 4.0116 kN and it was found that these values are consistent within the results obtained by the validation experiments. The microstructure of the weld joint was analyzed by optical microscope. The correlations between the predicted and experimental results were established.