This paper presents a systematic approach to develop the mathematical model for predicting the ultimate tensile strength, yield strength, and percentage of elongation of AA6351 aluminum alloy which is widely used in automotive, aircraft and defense Industries by incorporating (FSW) friction stir welding process parameter such as tool rotational speed, welding speed, and axial force. FSW has been carried out based on three factors five level central composite rotatable design with full replications technique. Response surface methodology (RSM) is employed to develop the mathematical model. Analysis of variance (ANOVA) Technique is used to check the adequacy of the developed mathematical model. The developed mathematical model can be used effectively at 95% confidence level. The effect of FSW process parameter on mechanical properties of AA6351 aluminum alloy has been analyzed in detail.
Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face-centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351-AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.
A systematic approach was presented to develop the empirical model for predicting the ultimate tensile strength of AA5083-H111 aluminum alloy which is widely used in ship building industry by incorporating friction stir welding (FSW) process parameters such as tool rotational speed, welding speed, and axial force. FSW was carried out considering three-factor five-level central composite rotatable design with full replications technique. Response surface methodology (RSM) was applied to developing linear regression model for establishing the relationship between the FSW process parameters and ultimate tensile strength. Analysis of variance (ANOVA) technique was used to check the adequacy of the developed model. The FSW process parameters were also optimized using response surface methodology (RSM) to maximize the ultimate tensile strength. The joint welded at a tool rotational speed of 1 000 r/min, a welding speed of 69 mm/min and an axial force of 1.33 t exhibits higher tensile strength compared with other joints.
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