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<p>In this study, friction stir welding (FSW) was used to perform a dissimilar weld on the aluminum alloys AA5083-H111 and AA6106-T6 with Sc being the interlayer. The experimental investigation is conducted using a three-factor, three-level Box–Behnken matrix (BBM) with response surface approach (RSA). The effects of rotational speed (RS) of 1300, 1450, and 1600&#xa0;rpm, weld speed (WS) of 30, 45, and 60&#xa0;mm/min, and tool plunge depth (TPD) of 0.1, 0.25, and 0.4&#xa0;mm with respect to frictional heating on mechanical concerts, such as hardness test and tensile strength test, were examined. The analysis of variance (ANOVA) showed that the key elements in determining joint soundness are RS, WS, and TPD. The projected optimum value of the welding reaction was confirmed after carrying out the validation run with the ideal constraints. From the proposed optimization element effectively regulates the fluctuating process constraints to provide contradictory response standards. From the examination, 242&#xa0;MPa tensile strength and 85 HV hardness were found to be the best values with the following welding process constraints: 1450&#xa0;rpm RS, 60&#xa0;mm/min WS, and 0.4&#xa0;mm TPD.</p>

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Analyzing the Influence of Tool Plunge Depth and Frictional Heat Generation in Friction Stir Welding of Scandium-Modified Dissimilar Aluminum Alloys

  • 期刊论文

  • 发表日期：

    2025年3月29日

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  • Nandakumar Kothandam,
  • Lenin Kasirajan,
  • Balamurugan Senthamaraikannan,
  • Premraj Yogaraj

摘要

In this study, friction stir welding (FSW) was used to perform a dissimilar weld on the aluminum alloys AA5083-H111 and AA6106-T6 with Sc being the interlayer. The experimental investigation is conducted using a three-factor, three-level Box–Behnken matrix (BBM) with response surface approach (RSA). The effects of rotational speed (RS) of 1300, 1450, and 1600 rpm, weld speed (WS) of 30, 45, and 60 mm/min, and tool plunge depth (TPD) of 0.1, 0.25, and 0.4 mm with respect to frictional heating on mechanical concerts, such as hardness test and tensile strength test, were examined. The analysis of variance (ANOVA) showed that the key elements in determining joint soundness are RS, WS, and TPD. The projected optimum value of the welding reaction was confirmed after carrying out the validation run with the ideal constraints. From the proposed optimization element effectively regulates the fluctuating process constraints to provide contradictory response standards. From the examination, 242 MPa tensile strength and 85 HV hardness were found to be the best values with the following welding process constraints: 1450 rpm RS, 60 mm/min WS, and 0.4 mm TPD.