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<p>Dissimilar friction stir welding (FSW) of magnesium AZ91D and aluminum AA6061-T6 poses significant challenges due to metallurgical incompatibility. Despite their potential in lightweight applications, comprehensive optimization of process parameters in SiC-reinforced AZ91D and AA6061-T6 FSW joints remains limited. This study investigates the influence of tool rotational speed (TRS), traverse speed (TS), and tool tilt angle (TTA), on the mechanical and metallurgical properties of these joints using central composite design (CCD) of Response Surface Methodology (RSM) to mathematically model FSW input parameters to fabricate dissimilar metals successfully. The analysis of variance (ANOVA) approach identified critical parameters. It validated the model’s prediction with a 95% confidence interval (CI) yielding R<sup>2</sup> values of 0.9881 for ultimate tensile strength (UTS), 0.9437 for strain, and 0.9815 for microhardness, indicating excellent predictive capability. Optimization revealed that the optimal microhardness, strain, and UTS in the stir zone (SZ) were 80.11 HV0.1, 6.34%, and 116.65&#xa0;MPa, respectively. Among 20 systematically designed experiments, the condition with 700&#xa0;rpm, TRS 30&#xa0;mm/min, and TS 2° TTA achieved the highest UTS (115.1 Mpa) and strain (6.7%) along with microhardness of 81.76 HV0.1, closely matching the model’s predicted optimum and confirming its accuracy and robustness across the design space. Additional confirmatory experiments outside the design space at intermediate parameter settings showed prediction errors below 5%, further validating the model’s robustness.</p>

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Process Optimization and Mechanical Characterization of SiC-Reinforced Friction Stir Welded AZ91D/AA6061-T6 Joints Using Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2025年11月21日

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  • Shwetanshu Gaurav,
  • Mohammad Zunaid,
  • Radhey Shyam Mishra

摘要

Dissimilar friction stir welding (FSW) of magnesium AZ91D and aluminum AA6061-T6 poses significant challenges due to metallurgical incompatibility. Despite their potential in lightweight applications, comprehensive optimization of process parameters in SiC-reinforced AZ91D and AA6061-T6 FSW joints remains limited. This study investigates the influence of tool rotational speed (TRS), traverse speed (TS), and tool tilt angle (TTA), on the mechanical and metallurgical properties of these joints using central composite design (CCD) of Response Surface Methodology (RSM) to mathematically model FSW input parameters to fabricate dissimilar metals successfully. The analysis of variance (ANOVA) approach identified critical parameters. It validated the model’s prediction with a 95% confidence interval (CI) yielding R2 values of 0.9881 for ultimate tensile strength (UTS), 0.9437 for strain, and 0.9815 for microhardness, indicating excellent predictive capability. Optimization revealed that the optimal microhardness, strain, and UTS in the stir zone (SZ) were 80.11 HV0.1, 6.34%, and 116.65 MPa, respectively. Among 20 systematically designed experiments, the condition with 700 rpm, TRS 30 mm/min, and TS 2° TTA achieved the highest UTS (115.1 Mpa) and strain (6.7%) along with microhardness of 81.76 HV0.1, closely matching the model’s predicted optimum and confirming its accuracy and robustness across the design space. Additional confirmatory experiments outside the design space at intermediate parameter settings showed prediction errors below 5%, further validating the model’s robustness.