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423515

OPTIMIZATION OF PROCESS PARAMETERS IN FRICTION STIR WELDING OF DISSIMILAR ALUMINUM ALLOYS: INSIGHTS INTO WELD QUALITY AND TOOL WEAR DYNAMICS

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Last updated: 27 Apr 2025

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Abstract

Abstract Friction stir welding (FSW) is a solid-state joining technique known for combining two workpieces through pressure and intense plastic deformation, avoiding melting. This method offers advantages such as lower energy consumption, enhanced mechanical properties, and reduced defects compared to traditional fusion welding techniques. The performance of FSW is highly influenced by key process parameters, including rotational speed, travel speed, and tilt angle, which govern critical outcomes such as maximum Temperature, ultimate tensile strength (UTS), and tool wear. This study investigates the interplay between these parameters in joining dissimilar aluminum alloys, 6061-T6 and 6082-T6. Using Response Surface Methodology (RSM), a robust statistical approach, the research optimizes and analyzes the relationships among the process parameters and their effects on weld quality and tool wear. Novel insights are presented regarding the linear relationship between tool wear and rotational speed and the inverse relationships with travel speed and tilt angle. Notably, higher rotational speeds increased tool wear while concurrently reducing tool surface roughness, highlighting the trade-offs in parameter selection.   Furthermore, the study identifies optimal FSW conditions to achieve a maximum temperature of 737°C, corresponding to a rotational speed of 2000 rpm, a travel speed of 10 mm/min, and a tilt angle 2°. These optimal settings improve weld quality and minimize tool wear, providing practical guidance for industrial applications. By focusing on the combined effects of rotational speed, travel speed, and tilt angle, this research fills a critical gap in understanding the simultaneous Optimization of weld quality and tool longevity in FSW of dissimilar aluminum alloys.

DOI

10.21608/jest.2025.355317.1111

Keywords

FSW, dissimilar aluminum, Rotation speed, Tool wear, Temperature, UTS

Authors

First Name

Ibrahim

Last Name

Sabry

MiddleName

-

Affiliation

Department of Mechanical Engineering, Benha Faculty of Engineering, Benha University, Benha, 13511, EGYPT.

Email

ibrahim.sabry@bhit.bu.edu.eg

City

-

Orcid

0000-0002-8582-0619

Volume

22

Article Issue

2

Related Issue

55231

Issue Date

2025-04-01

Receive Date

2025-01-24

Publish Date

2025-04-01

Page Start

40

Page End

60

Print ISSN

2090-5882

Online ISSN

2090-5955

Article File

JEST_Volume 22_Issue 2_Pages 40-60.pdf

PDF . 1.2MB

Link

https://jest.journals.ekb.eg/article_423515.html

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http://journals.ekb.eg?_action=service&article_code=423515

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423,515

Type

Original Article

Type Code

1,211

Publication Type

Journal

Publication Title

Journal of the Egyptian Society of Tribology

Publication Link

https://jest.journals.ekb.eg/

MainTitle

OPTIMIZATION OF PROCESS PARAMETERS IN FRICTION STIR WELDING OF DISSIMILAR ALUMINUM ALLOYS: INSIGHTS INTO WELD QUALITY AND TOOL WEAR DYNAMICS

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Article

Created At

27 Apr 2025