Optimization of Process Parameters of Friction Stir Welding of Dissimilar Aluminum Alloys (AA6061-T6 and AA6082-T6)

Objective: Friction Stir Welding (FSW) is a process in which the tool is given the desired rotation and feed to produce the heat required to weld the joints. The recrystallization temperature is achieved thereby leading to formation of strong weld without the melting of joining materials. In this examination, the Friction Stir Welding of different 6 series Alloy flat pieces (AA6061 and AA6082) of 6 mm thickness was explored. Methods/Analysis: Experimental conditions were finalized and this welding method was performed on plates at various tool rotational velocities of 800, 1100 and 1400 rpm by shifting the welding speeds i.e. 120, 150 and 180 mm/min and tool pin profiles (cylindrical strung and decrease threaded). Tensile tests were done on the acquired welded joints and the outcomes had been investigated utilizing Taguchi L9 strategy. Findings: It was concluded from the present study that the tensile strength is mostly affected by tool rotational speed. Confirmation experiment shows that error (%) associate with tensile strength is 4.03. O p t i m a l setting of process parameters for tensile strength is 1400 rpm, 120 mm/min with cylindrical threaded tool (TPI-22). Application/Improvement: Friction Stir Welding method can emerge as an efficient process used in welding of aluminum alloys with different compositions.