Examination and Optimization of Friction Stir Welding Process Parameters of AA6092 Alloys

Abstract

In this present examination, AA6092 alloys are friction-stir welded at various welding conditions to develop a welded joint with optimal ultimate tensile strength (UTS) and microhardness. This work deals with replacement of application of AA6061 alloys as bumper and bonnet by means of AA6092 alloys and this alloys tensile strength and microhardness is further increased by performing friction stir welding. This study investigates the performance of the friction stir welded butt joints of AA6092 alloys by varying the FSW process parameters such as tool rotational speed (TRS), welding speed (WS), axial load (AL), tool tilt angle (TTA), tool pin profile (TPP), shoulder diameter (SD), etc. In the current investigation, the empirical relationships are developed between most contributing FSW process parameters (TRS, WS, and AL) and their output responses (UTS and weld nugget microhardness (WNH)). The optimal UTS and WNH is predicted by the desirability approach of response surface methodology (RSM). The conforming values of input FSW process parameters are TRS of 1451.67 rpm, WS of 42.22 mm/min, and AL of 5.29 kN. For the existing examination, calculated UTS and WNH are 465.6 MPa and 151.8 HRB respectively, and the results of validation experiments are also invariable with these values.