Title: Optimising Friction Stir Welding parameters to maximise tensile strength of AA6061 aluminium alloy joints

Authors: K. Elangovan, V. Balasubramanian, S. Babu, M. Balasubramanian

Addresses: Department of Production Engineering, Sathyabama University, Chennai, Tamil Nadu, India. ' Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar – 608 002, Tamil Nadu, India. ' Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar – 608 002, Tamil Nadu, India. ' Department of Mechanical Engineering, Mamallan Institute of Technology, Sriperumbudur, Tamil Nadu, India

Abstract: AA6061 aluminium alloy (Al-Mg-Si) has widely accepted in the fabrication of light weight structures. Friction Stir Welding (FSW) process is an emerging solid-state joining process which offers several advantages over other fusion welding processes. The welding parameters such as tool rotational speed, welding speed, axial force and tool pin profile play a major role in deciding the joint strength. An attempt has been made to develop a mathematical model to predict tensile strength. Response surface method (RSM) has been used to develop the model and it is optimised using Hooke and Jeeves search technique to attain maximum tensile strength.

Keywords: aluminium alloys; friction stir welding; FSW; rotational speed; welding speed; axial force; tool pin profile; tensile strength; design of experiments; DOE; Hooke and Jeeves algorithm; alloy joints; AA6061 alloy; joint strength; esponse surface methodology; RSM.

DOI: 10.1504/IJMR.2008.019213

International Journal of Manufacturing Research, 2008 Vol.3 No.3, pp.321 - 334

Published online: 02 Jul 2008 *

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