Aluminum alloys based on response surface methodology optimization and categorization of FSW for AA7075 & AA6082

The process of fusing two or more metal pieces to enhance their qualities is known as frictional stir welding (FSW). The tensile strength, yield strength, and fracture of the location of the jointed metals vary based on the rotational speed (RS), tilt angle (TA), and welding speed (WS) of the tool. However, a lengthy test cycle and poor precision frequently affect the FSW process’s performance. This paper proposes a response surface methodology (RSM) based optimization of FSW of aluminum alloys AA7075 and AA6082. The primary objective is to improve the mechanical attributes of welded aluminum alloys. The Box-Behnken design (BBD) was chosen for RSM to generate higher-order response surfaces. The microstructure and macrostructure are assessed, as well as whether the fracture location is brittle or ductile, using scanning electron microscopy (SEM) examination. The optimized parameters are found to be RS of 900 rpm, WS of 90 mm/min, and TA of 2°. The ultimate tensile strength (UTS) of 217 MPa and yield strength of 189 MPa are observed with the optimized welding parameters. Additionally, the proposed approach achieves a high R2 and adjusted R2 values of 0.9949 and 0.9877 correspondingly. This research exhibits that the proposed method helps find the optimal welding parameters.