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<p>Friction stir welding is widely adopted for joining aluminum alloys in critical applications such as shipbuilding, aerospace, and the automotive industry due to its ability to produce high-integrity joints with excellent mechanical properties. This study investigates the fatigue crack growth behavior of FSW joints in marine-grade Al-Mg-Cr alloy, with a focus on understanding the influence of key process parameters. To systematically evaluate the effects of pin diameter, shoulder diameter, tool rotational speed, and welding speed on the fatigue crack growth rate (FCGR), the response surface methodology (RSM) was employed using a central composite design (CCD) with five levels for each parameter. The analysis revealed that the optimal combination for minimizing FCGR consisted of a 9&#xa0;mm pin diameter, 18&#xa0;mm shoulder diameter, 560&#xa0;rpm tool rotation speed, and 400&#xa0;mm/min welding speed. In addition to fatigue performance, this study also examined mechanical and metallurgical characteristics, including hardness, microstructure, and residual stress distribution, establishing their correlation with fatigue behavior. The results indicated that larger pin and shoulder diameters tend to deteriorate fatigue performance, likely due to increased heat input and altered material flow. Although tool rotational speed and welding speed individually had limited effects, their combined influence significantly affected the FCGR, highlighting the importance of parameter interaction.</p>

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Investigation of Influence of Process Parameters on the Metallurgical and Fatigue Properties of Friction Stir Welded Al-Mg-Cr Alloy Using Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Ratnesh Kumar Raj Singh,
  • Rajesh Prasad,
  • Sunil Pandey,
  • Satish Kumar Sharma

摘要

Friction stir welding is widely adopted for joining aluminum alloys in critical applications such as shipbuilding, aerospace, and the automotive industry due to its ability to produce high-integrity joints with excellent mechanical properties. This study investigates the fatigue crack growth behavior of FSW joints in marine-grade Al-Mg-Cr alloy, with a focus on understanding the influence of key process parameters. To systematically evaluate the effects of pin diameter, shoulder diameter, tool rotational speed, and welding speed on the fatigue crack growth rate (FCGR), the response surface methodology (RSM) was employed using a central composite design (CCD) with five levels for each parameter. The analysis revealed that the optimal combination for minimizing FCGR consisted of a 9 mm pin diameter, 18 mm shoulder diameter, 560 rpm tool rotation speed, and 400 mm/min welding speed. In addition to fatigue performance, this study also examined mechanical and metallurgical characteristics, including hardness, microstructure, and residual stress distribution, establishing their correlation with fatigue behavior. The results indicated that larger pin and shoulder diameters tend to deteriorate fatigue performance, likely due to increased heat input and altered material flow. Although tool rotational speed and welding speed individually had limited effects, their combined influence significantly affected the FCGR, highlighting the importance of parameter interaction.