Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology

Article

Safeen, Wasif, Hussain, Salman, Wasim, Ahmad, Jahanzaib, Mirza, Aziz, Haris and Abdalla, H. 2016. Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology. The International Journal of Advanced Manufacturing Technology. 87 (5-8), pp. 1765-1781. https://doi.org/10.1007/s00170-016-8565-9
AuthorsSafeen, Wasif, Hussain, Salman, Wasim, Ahmad, Jahanzaib, Mirza, Aziz, Haris and Abdalla, H.
Abstract

In this research, an attempt has been made to develop mathematical models for predicting mechanical properties including ultimate tensile strength, impact toughness, and hardness of the friction stir-welded AA6061-T6 joints at 95 % confidence level. Response surface methodology with central composite design having four parameters and five levels has been used. The four parameters considered were tool pin profile, rotational speed, welding speed, and tool tilt angle. Three confirmation tests were performed to validate the empirical relations. In addition, the influence of the process parameters on ultimate tensile strength, impact toughness, and hardness were investigated. The results indicated that tool pin profile is the most significant parameter in terms of mechanical properties; tool with simple cylindrical pin profile produced weld with high ultimate tensile strength, impact toughness, and hardness. In addition to tool pin profile, rotational speed was more significant compared to welding speed for ultimate tensile strength and impact toughness, whereas welding speed showed dominancy over rotational speed in case of hardness. Optimum conditions of process parameters have been found at which tensile strength of 92 %, impact toughness of 87 %, and hardness of 95 % was achieved in comparison to the base metal. This research will contribute to expand the scientific foundation of friction stir welding of aluminum alloys with emphasis on AA6061-T6. The results will aid the practitioners to develop a clear understanding of the influence of process parameters on mechanical properties and will allow the selection of best combinations of parameters to achieve desired mechanical properties.

KeywordsFriction stir welding; Parameters; Response surface methodology; Tensile strength; Impact toughness; Hardness
JournalThe International Journal of Advanced Manufacturing Technology
Journal citation87 (5-8), pp. 1765-1781
ISSN1433-3015
0268-3768
Year2016
PublisherSpringer Verlag
Accepted author manuscript
Digital Object Identifier (DOI)https://doi.org/10.1007/s00170-016-8565-9
Publication dates
Print12 Mar 2016
Publication process dates
Deposited17 Jan 2017
Accepted29 Feb 2016
Copyright informationThe final publication is available at Springer via http://dx.doi.org/10.1007/s00170-016-8565-9
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