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Aluminum can't successfully be arc welded in an air environment, due to the affinity for oxygen. If fusion welded in normal atmosphere oxidization readily happens and this outcome in both slag inclusion and porosity in the weld, greatly reducing its mechanical properties. This work presents a systematic approach to develop the suggestion model by three (ANN), response surface methodology (RSM) and regression analysis (RA) for predicting the ultimate tensile strength, percentage of elongation and hardness of 6061 aluminum alloy which is widely used in automotive, aircraft and defense industries by incorporating (FSW) friction stir welding process parameter such as tool rotation speed, welding speed and material thickness. The results obtained through regression analysis and response surface methodology were compared with those through artificial neural networks.

In this paper, a comprehensive practical study in mechanical properties and cost welding of welded Aluminum 6061 pipe using three different types of welds, Metal Inert Gas (MIG), Tungsten Inert Gas (TIG) and Friction Stir Welding (FSW) with rotation speed (1800 RPM) and travel speed 4mm/min. The mechanical properties of the weld have been also investigated using the hardness, elongation and tensile tests. The microstructure of the welds, including the nugget zone and heat affected zone, has been compared with these three methods using optical microscopy and the basis of heat input in weld joint. The results show that FSW improves the mechanical properties of welded joints compare Tungsten Inert Gas (TIG) and Metal Inert Gas (MIG), respectively.

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