Abstract
Design structures made of aluminium alloy and steel are useful to meet the needs of automotive industry such as light weight and higher strength. An effective joining technique to join light weight metals such as aluminium alloys with steel is required. Friction stir spot welding (FSSW) is relatively a new solid state process and it is a derivative of Friction Stir Welding. It creates a spot, lap joint weld without bulk melting. The FSSW parameters such as tool rotational speed, plunge depth, and dwell time plays a major role in determining the strength of the joints and need to be optimized to get quality joints. In this investigation, a central composite rotatable design with three factors and five levels was chosen to minimize the number of experimental conditions. Response surface methodology (RSM) was applied to optimize the FSSW parameters to attain maximum lap shear strength of the spot weld.
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