Predicting tensile strength of filler added friction stir welded AA6082 and AA5052 dissimilar joint

Abstract

Friction Stir Welding (FSW) process parameters and tool parameters are playing pivotal role in the weld joint characteristics. The combination is selected for the investigation of AA6082 and AA5052, which finds major application in ship structural frame and building constructions. Along with these usual parameters the composition of filler elements is considered in this work to improve the weld joint strength. The process parameters considered in this study are rotational speed, welding speed, shoulder penetration, filler holes center distance, and powder mixing ratio. The Central Composite Design (CCD), the most commonly used Response Surface Methodology (RSM) is considered to develop the prediction equation. A validation analysis is carried out and the results were compared with the relative impact of input parameters on tensile strength. The maximum tensile strength of fabricated joint was obtained with the process parameters combination of 1000 rpm rotational speed, 125 mm/min welding speed, 0.15 mm shoulder penetration, 2 mm filler holes center distance, and powder mixing ratio of 95% Mg and 5% Cr.