Modelling and analysis of process parameters in friction stir welding of AA5083-H321 using response surface methodology

Abstract

The Aluminum–Magnesium alloy AA5083 finds large applications in the marine industry, aerospace industry, and automobile industry due to its light weight and high strength. Friction stir welding has been rapidly developed as an advanced joining process due to its high quality aluminum weld and environment friendly metal joining applications. This process gives a good strength as well as good surface finish to the welded parts as compared to the conventional joining processes, like gas metal arc welding, simple arc welding etc. In this research work, aluminum alloy 5083-H321 sheets have been selected for joining through friction stir welding with a cylindrical pin profile stirring tool. Four different process parameters namely; traverse speed, tool tilt angle, rotational speed and dwell time have been investigated by conducting experiments using central composite design. Empirical relationships between the input process parameters and the responses (tensile strength and percentage elongation) have been developed through response surface methodology. The developed models reveal that tool tilt angle and tool rotational speed have more dominating effect on the investigated responses as compared to the other process parameters.