Parametric optimization and tensile behaviour analysis of AA6061 - ZrO2 - C FSW samples using Box-Behnken method

Abstract

In present work, optimization of friction stir welding (FSW) process parameter (tool rotational speed, welding speed and axial load) to maximize the output responses of mechanical properties (Tensile strength and Hardness) stir cast 92% of AA6061 matrix material, 6% of Zirconia (ZrO2) and 25 of graphite (C). The Box- Behnken three levels and three factors are used to identify the number of experiment. The regression equation is developed and correlated by significant input welding process parameters and output responses tensile strength and hardness of FS welded AMMCs using statistical software Design Expert V8. The desirability functions are using finding the optimized FSW process parameters. 190 MPa tensile strength and 45 HRB hardness are obtained by optimized process parameters like 808 rpm tool rotational speed, 46.88 mm/min welding speed and 5.23 kN axial load.