Development of mechanical property prediction model and optimization for dissimilar aluminum alloy joints with the friction stir welding (FSW) process

Friction stir welding (FSW) is a solid-state joining process used to weld dissimilar aluminum alloys with varying material properties and compositions. Unlike traditional welding methods, FSW does not involve melting the materials being welded but instead uses a rotating tool to heat and stir the materials until they are in a plastic state. The process results in a welded joint with high strength, excellent ductility, and minimal distortion, making it a popular choice in various industries, including aerospace, automotive, and marine. AA6061-T6 (Mg-Si) and AA7075 (Al-Zn-Mg-Cu) aluminum alloys are one of the most popular grades of aluminum alloys used in current manufacturing industries, such as aerospace and automotive, joined by the Friction Stir Welding Process (FSW) technique. Taguchi orthogonal array (L9) experimental design was applied to reduce the number of insignificant factors in the process. First, the study determines three welding factors: rotation speed, travel speed, and pin eccentricity. Investigations found that travel speeds significantly on tensile strength (Ts) and elongation ( %El), but the rotational speed and tool eccentricity did not affect Ts and %El. Furthermore, considering the fabricated parameters on the hardness (HV) of the joint, it was found that all factors unaffected the HV of the joint zone at a 95 % confidence level. Next, examine the microstructure; Mg2Al3 and Al2O3 intermetallic compounds were found in the weld. Therefore, investigating the crystallite size found that welding significantly affects the crystallite size. Finally, consider the fracture surface, experimental condition A2B1C2 (optimal parameter), which is the parameter with the highest tensile strength having dimple fracture characteristics. On the other hand, the welding condition A1B3C3, the parameter with the lowest tensile strength, Small and fine dimple fracture with cleavage fracture. Because the material is highly ductile and can undergo large deformations before it is damaged. On the other hand, materials with low tensile strength exhibiting cleavage fracture indicate that the materials are brittle and can break easily under stress