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Optimization of process parameters in friction stir welding of dissimilar aluminum alloys (AA6061–T6 and AA5052–H32)

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Abstract

Friction stir welding (FSW) is a solid-state welding method for the welding of aluminum alloys and has been used in aerospace, railway, automotive, and marine applications. Solid-state welding processes solve several problems that occur during fusion welding of Al-alloys like HAZ liquation cracking, porosity, and segregation. Aluminum alloys of two different series AA5052 and AA6061 thickness of 6 mm are FS welded using process parameters like tool rotational speed (900, 1100, 1400) rpm, transverse speed (40, 50, 60) mm/min, and pin profiles (cylindrical, conical, and square). This article aims to optimize the mechanical and metallurgical properties of the above dissimilar combination to evaluate the performance and characteristics of the welded joints. The combined Taguchi and Grey relation analysis experimental method was chosen to construct the number of welding experiments. The plates are successfully welded, and the welded plates are tested at room temperature to examine their tensile strength and hardness. The findings indicate that the maximum tensile strength of 183.04 MPa, which is 79.58% with AA5052-H32 and 59.05% with AA6061-T6 individually of the base material strength and the square pin profile, the rotational speed of 1400 rpm, and the transverse speed of 40 mm/min are the optimum parameters for joining these dissimilar joints. Tool pin profile has the most prominent FSW process parameters, with a 54.15% contribution.

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Acknowledgements

The authors would like to thank Addis Ababa University for providing access to the research facilities for performing the experiments and review literature on this study.

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The Authors received no financial support for this research, authorship and publication of this research.

Authors declare that there is no potential conflict of interest with respect to the research, authorship of this article.

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Authors and Affiliations

  1. School of Mechanical and Industrial Engineering, Addis Ababa Institute of Technology, Addis Ababa University, King George VI St, 1000, Addis Ababa, Ethiopia

    Wondu Tesfaye Heramo & Henok Zewdu Workneh

  2. School of Mechanical and Automotive Engineering, College of Engineering and Technology, Dilla University, 419, Dilla, Ethiopia

    Wondu Tesfaye Heramo

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  1. Wondu Tesfaye Heramo
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Contributions

W.T.H. and H.Z.W. conceived and designed the experiments; W.T.H. performed the experiments under the supervision of H.Z.W.; W.T.H. and H.Z.W. analyzed the data and wrote the paper.

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Correspondence to Henok Zewdu Workneh.

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Heramo, W.T., Workneh, H.Z. Optimization of process parameters in friction stir welding of dissimilar aluminum alloys (AA6061–T6 and AA5052–H32). Int J Adv Manuf Technol 129, 4473–4489 (2023). https://doi.org/10.1007/s00170-023-12546-z

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