Performance analysis of dissimilar friction stir welded aluminium alloy AA5052 and HSLA steel butt joints using response surface method

The requirement of weight reduction, high thermal conductivity and strength at low temperatures and high corrosion resistance has identified the use of Al alloys together with steel in various fields. The use of Al alloys together with steel warrants efficient joining of Al alloys with steels. Friction stir welding (FSW) is a potential candidate for the joining of difficult-to-weld similar and dissimilar materials due to its inherent advantages as a solid state joining process. In order to speed up the research activities that lead to industrial level implementation of FSW of dissimilar Al alloys and steels, modelling and simulation can play a vital role. In this work, a central composite-response surface method (RSM) model is developed to predict the ultimate tensile strength (UTS) of friction stir-welded dissimilar Al alloy AA5052 H32 and HSLA steel IRS M-42-97. The adequacy of the model is verified by the analysis of variance (ANOVA) and computed values of the actual and adjusted R2 values. The model is validated by the results of experimental trials at parameter combination other than that experimented as per the DOE matrix and found in agreement with an average error of −0.34 %. From the analysis of the developed model, it is observed that the UTS of the joint is very sensitive to the primary FSW parameters, and, as such, the range of primary FSW parameters that could produce significant joint strength is very narrow. Also, it is observed that the tool rotational speed, welding speed and axial force have a significant interaction effect on the UTS of the joint. The analysis of the model and discussion on the effect of FSW parameters on the tensile strength of the joint are supported by the results of scanning electron microscopy and EDS analysis at the joint interface of selected joints.

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