Optimization of Process Parameters for Enhanced Mechanical Properties in FSW of Dissimilar Aluminium Alloys 6061 and 6082

Abstract

This study investigates the optimization of process parameters and mechanical attributes (tensile strength and hardness) of friction stir welded (FSW) joints between different aluminium alloys, namely 6082 and 6061. Four unique process parameters were established utilizing a L4 design of experiments methodology. Each parameter set was applied to join the aluminium grades using the FSW process, resulting in four distinct samples. Following mechanical testing, encompassing hardness and tensile evaluations, the integrity and strength of the welds were tested. The data from these tests were analyzed with Minitab software to conduct ANOVA optimization, with the objective of identifying the ideal process parameters that improve weldment quality and mechanical attributes.