Analysis of factors influencing tensile strength in dissimilar welds of AA2024 and AA6061 produced by Friction Stir Welding (FSW)

Abstract Friction Stir Welding (FSW) is a solid state joining technique which is universally used for joining of aluminium alloys in marine, aerospace, automotive and many other applications of commercial importance. In the present study, the effect of FSW parameters on the weldability of dissimilar aluminium alloys called AA2024 and AA6061 was investigated. The two plates were aligned perpendicular to the rolling directions and the welding was carried out. The main objective of the experiment was to find out the maximum tensile strength. The experiments were conducted on a milling machine. Three-factor three levels Box–Behnken matrix in response surface methodology is employed to carry out the experimental investigation. The “Design Expert 8.0” software was used for regression and graphical analyses of data collected. Analysis of variance was used to check the validity of the model. Designed FSW experiments were carried out to get high strength welding by controlling the rotational, welding speed and tool pin diameter. The tensile tests were carried under tension at room temperature in order to analyse the mechanical response.