Abstract
AA2024 Aluminum alloy has predominantly been used for making aircraft engine parts and frames. The normal welding process does not apply to join aluminum alloy. Because Al and its alloy have a low melting point and high thermal conductivity, which can easily lead to porosity and partially melting; as a result, Friction Stir Welding (FSW) has been employed to solve these issues. This work focused on the parameter’s optimization to the conceived maximum strength of AA2024 aluminum alloy. Four major parameters viz., tilt angle, shoulder diameter, welding speed, and rotational speed were selected. The formulation of empirical relationship was made using statistical tool design of experiment, and analysis of variance has been used to check the developed model’s adequacy. Furthermore, the response surface graphs were used to identify the maximum strength and its corresponding FSW parameters. The joint obtained the full power from the experimental results at a tilt angle of 1.5 deg., traverse speed of 15 mm/min, speed of tool 1100 rpm, and diameter of shoulder 24 mm.
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