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<p>In this work, the joint strength of MIG-welded AA6082-AA7075 joints with filler ER4043 was improved through friction stir processing, with variation in processing parameters. A mathematical model was developed to predict output responses based on input parameters using a face-centered central composite design. Analysis of variance (ANOVA) results showed that the tool rotational speed and welding speed were the most influential parameters on the response variables. The MIG-welded joints exhibited a coarse-grained structure and fusion zone defects, resulting in a minimum tensile strength of 152.68&#xa0;MPa. For MIG + FSPed joints, a minimum tensile strength of 189.71&#xa0;MPa was recorded at tool rotational speed of 1300&#xa0;rpm, welding speed of 50&#xa0;mm/min, and tool tilt angle of 3°, and a maximum tensile strength of 247.39&#xa0;MPa was attained at tool rotational speed of 1050&#xa0;rpm, welding speed of 70&#xa0;mm/min, and tool tilt angle of 0°.</p>

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Optimization of Process Parameters of Friction Stir-Processed Dissimilar MIG-Welded Joints of AA6082 and AA7075 by Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2026年3月26日

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  • Vinay Kumar,
  • Vipin,
  • R. S. Mishra

摘要

In this work, the joint strength of MIG-welded AA6082-AA7075 joints with filler ER4043 was improved through friction stir processing, with variation in processing parameters. A mathematical model was developed to predict output responses based on input parameters using a face-centered central composite design. Analysis of variance (ANOVA) results showed that the tool rotational speed and welding speed were the most influential parameters on the response variables. The MIG-welded joints exhibited a coarse-grained structure and fusion zone defects, resulting in a minimum tensile strength of 152.68 MPa. For MIG + FSPed joints, a minimum tensile strength of 189.71 MPa was recorded at tool rotational speed of 1300 rpm, welding speed of 50 mm/min, and tool tilt angle of 3°, and a maximum tensile strength of 247.39 MPa was attained at tool rotational speed of 1050 rpm, welding speed of 70 mm/min, and tool tilt angle of 0°.