Experimental and mathematical evaluation of thermal and tensile properties of friction stir welded joint

The aim of this experiment is to develop a mathematical model of friction stir welded joint of aluminium alloy 6061-T6 for correlating the process parameters (rotational speed, welding speed) with output responses (maximum process temperature, yield strength, ultimate tensile strength and % elongation). This developed model will establish an empirical relationship between the modelled values and experimental values. Experiments of AA 6061-T6 FSW butt joints were carried out by using a 'full factorial' design. Analysis of variance and scatter diagram were utilised to assess the significance of the factors and adequacy of the models developed for response variables. The optimum values of output responses, i.e., Tmax, YS, UTS and %E, were found as 417.98°C, 123.92 MPa, 134.42 MPa and 12.07, respectively, at optimum welding parameters (1,000 rpm and 40 mm/min). The influence of FSW process parameters on temperature distribution as well as tensile properties has been analysed in this study.