Optimization of friction welding process parameters for Joining Al6082 and mild steel using RSM

Abstract

The goal of this research is to evaluate the improvement of solid state joints made of different materials, Al6082 Aluminum and Mild Steel. Rotary friction welding was used to create the joints (RFW). The process parameters of friction welding machine was optimised using response surface methodology (RSM) to achieve the maximum tensile strength of the joint. Dissimilar welding of metals is being a difficult process due to its variance in mechanical properties, co-efficient of thermal expansion, thermal conductivity and other properties. There is a big mismatch between the metals when welded. In this case the friction welding is found out be a better process than other conventional welding. The friction welding of Aluminium and Mild steel was a challenging one due to its difference in mechanical and physical characteristics. One more problem is the formation of intermetallic compounds at the interface. This intermetallics may lead to brittleness at the weld center and giving way for failure. So this should be reduced. In this study the optimization of welding parameter is done by using RSM. Various combinations of parameter has been set and welded. Their tensile properties and characterisation has been analysed.