Abstract
In this research work, dissimilar aluminium alloys of AA7075-T651 and AA6061 were friction stir butt welded by varying the FSW parameters such as tool tilt angle, tool offset and tool pin diameter by using central composite design of response surface methodology (RSM). Experiments were designed by considering three factors and five levels having 20 experimental runs. Ultimate tensile strength and microhardness were employed as responses. Desirability approach has been used to optimize the FSW parameters. Analysis of variance was employed to check the adequacy of the developed model at 95% confidence level. This study revealed that tool pin diameter and tool offset were most significant factors on deciding the tensile strength and microhardness of the joint. It was observed that the joint fabricated with 6 mm pin diameter, 0.9 mm tool offset and 3 degree tilt angle exhibited the maximum tensile strength and microhardness of 267 MPa and 121 Hv when compared to the other joints. Fractography analysis revealed that the FSW joint with maximum tensile strength shows fine dimples which indicates ductile mode of failure.
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