Optimisation of Corrosion and Tensile Properties of Dissimilar AA7075/AA2024 Friction Stir Welds

This work concentrated on optimising the FSW process parameters to improve the weld joint properties of dissimilar FSW of AA 7075-T6/ AA 2024-T3 alloys. A newly designed hybrid polygonal tool is employed to fabricate welds to increase production. For this study, the Response surface method (RSM) built on a central composite methodology is employed for data analysis, experiment design, and optimisation. The mathematical models that predicted the tensile characteristics and corrosion rate of dissimilar 7075–2024 FSW joints with a certain degree of confidence were established using the RSM approach. Utilising the analysis of variance approach, the created models were confirmed. The best FSW processing parameters were suggested following experimental work.