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<p>This study optimized the submerged friction stir welding (SFSW) process for dissimilar aluminum alloys, AA6061 and AA6082, to enhance weld quality through mechanical and metallurgical improvements. A Box-Behnken Design of Experiments (DOE) approach was employed, involving a three-factor, three-level matrix to evaluate the effects of tool rotational speed, welding speed, and water head on the tensile strength and microhardness of the welds. Seventeen experimental trials were conducted to identify the optimal process parameters, which were found to be 1000&#xa0;rpm tool rotational speed, 40&#xa0;mm/min welding speed, and 20&#xa0;mm water head. These conditions resulted in a tensile strength of 188&#xa0;MPa and a microhardness of 105 HV, validated through experimental and predictive correlations. Higher tool rotational speeds facilitated better material mixing, while optimal water head levels balanced heat dissipation and retention, ensuring fine grain structure formation and minimizing heat-affected zones. Metallurgical analysis revealed a tightly packed grain structure in the weld zone, and fractographic studies indicated a complex ductile-brittle fracture mechanism, supported by XRD analysis.</p>

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Optimization of SFSW Parameters in Dissimilar Aluminum Alloy Processing

  • 期刊论文

  • 发表日期：

    2025年5月2日

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  • L. Shunmugaraj,
  • M. S. Starvin,
  • R. Pandiyarajan

摘要

This study optimized the submerged friction stir welding (SFSW) process for dissimilar aluminum alloys, AA6061 and AA6082, to enhance weld quality through mechanical and metallurgical improvements. A Box-Behnken Design of Experiments (DOE) approach was employed, involving a three-factor, three-level matrix to evaluate the effects of tool rotational speed, welding speed, and water head on the tensile strength and microhardness of the welds. Seventeen experimental trials were conducted to identify the optimal process parameters, which were found to be 1000 rpm tool rotational speed, 40 mm/min welding speed, and 20 mm water head. These conditions resulted in a tensile strength of 188 MPa and a microhardness of 105 HV, validated through experimental and predictive correlations. Higher tool rotational speeds facilitated better material mixing, while optimal water head levels balanced heat dissipation and retention, ensuring fine grain structure formation and minimizing heat-affected zones. Metallurgical analysis revealed a tightly packed grain structure in the weld zone, and fractographic studies indicated a complex ductile-brittle fracture mechanism, supported by XRD analysis.