Friction stir welding parameters optimization for tailored welded blank sheets of AA1100 with AA6061 dissimilar alloy using response surface methodology

Abstract

Presently, tailored welded blank (TWB) sheets have found various applications in automotive, aeronautical and many other industries. The most popular method for production of TWB sheets is friction stir welding (FSW) process. In this investigation, an attempt has been made to develop an empirical relationship between FSW parameters and tensile strength of the friction stir welded AA1100 with AA6061 aluminum alloys. To obtain the desired strength, it is essential to have a complete control over the relevant process parameters to maximize the tensile strength for forming of TWB on which the quality of a weldment is based. Therefore, it is very important to select and control the welding process parameter for obtaining maximum strength. To achieve this statistical tool such as response surface method (RSM), analysis of variance (ANOVA), Students t-test, coefficient of determination, etc., can be applied to define the desired response through developing mathematical model s to specify the relationship between the output response and input variables. Four factors, five levels central composite design have been used to minimize number of experimental conditions. The developed mathematical relationship can be effectively used to predict the tensile strength of FSW joint s of AA1100/ AA6061 aluminum alloy at 95% confidence level.

Keywords:

• Friction stir welding
• tailored welded blank
• aluminium alloys
• response surface methodology

Acknowledgement

The first two authors acknowledge the services rendered by the CEMAJOR personnel of Annamalai University, Annamalai Nagar, Tamilnadu, India, who supported this work by the way of conducting critical tests for analysis.