Title: Optimisation and sensitivity analysis of friction stir spot-welding process parameters for joining AA 6061 aluminum alloy

Authors: R. Karthikeyan; V. Balasubramanian

Addresses: Center for Materials Joining and Research, Department of Manufacturing Engineering, Annamalai University, Annamalainagar 608 002, Chidambaram, Tamil Nadu, India ' Center for Materials Joining and Research, Department of Manufacturing Engineering, Annamalai University, Annamalainagar 608 002, Chidambaram, Tamil Nadu, India

Abstract: Al-Mg-Si aluminum alloy has gathered wide acceptance in automotive industries requiring a high strength-to weight ratio and good corrosion resistance. The friction stir spot welding process is a variant of linear friction stir welding process in which the material is being welded without bulk melting. The FSSW parameters such as tool rotational speed, plunge rate, plunge depth, dwell time play major role in determining the strength of the joints. A central composite rotatable design with four factors and five levels has been chosen. An empirical relationship is established to predict the tensile shear fracture load of friction stir spot-welded AA6061 aluminum alloy by incorporating independently controllable FSSW process parameters. Response Surface Methodology is applied to optimise the FSSW parameters to attain maximum lap shear strength of the spot weld and sensitivity analysis is carried out to study the impact of process parameters on output.

Keywords: friction stir welding; FSW; FSSW; friction stir spot welding; aluminum alloys; design of experiments; DOE; optimisation; sensitivity analysis; process parameters; tool rotational speed; plunge rate; plunge depth; dwell time; tensile shear fracture; response surface methodology; RSM; lap shear strength.

DOI: 10.1504/IJMR.2012.048696

International Journal of Manufacturing Research, 2012 Vol.7 No.3, pp.257 - 272

Available online: 22 Aug 2012 *

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