Effect of process parameters on friction stir welding of aluminium alloy AA6082–T6 with an interlayer using response surface methodology

Abstract In the present study, the effects of variation of process parameters on the mechanical properties of friction stir welded A6082–T6 aluminium alloy joints with Zinc (Zn) interlayer are experimentally investigated. Four process parameters, viz. rotational speed, welding speed, interlayer thickness and tool pin diameter are selected to fabricate the Friction Stir Welding (FSW) joints. After filling the Zn particles into the gap maintained between the plates, FSW is performed using different process parameters. Thereafter, tensile and impact strength tests are performed to evaluate the performance of the joints. It is analyzed that the tensile and impact strength of the joints vary from 121 to 197 MPa and 6 to 17 J, respectively. Subsequently, mathematical models are developed using Response Surface Methodology (RSM) to predict the effect of FSW process parameters on the tensile and impact strength of joints. Analysis of Variance (ANOVA) is used to check the level and degree of direct effect of process variables on the tensile and impact strength of the joints. It is observed from the results that tool rotational speed is the most influential process parameter, which enhances the mechanical properties of FSW joints, whereas an increase in welding speed reduces the mechanical properties of the joints.