OPTIMIZATION OF PROCESS PARAMETERS IN FRICTION STIR WELDING OF DISSIMILAR ALUMINUM ALLOYS: INSIGHTS INTO WELD QUALITY AND TOOL WEAR DYNAMICS | ||||
| Journal of the Egyptian Society of Tribology | ||||
| Volume 22, Issue 2, April 2025, Page 40-60 PDF (1.17 MB) | ||||
| Document Type: Original Article | ||||
| DOI: 10.21608/jest.2025.355317.1111 | ||||
 View on SCiNiTO | ||||
| Author | ||||
Ibrahim Sabry  
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| Department of Mechanical Engineering, Benha Faculty of Engineering, Benha University, Benha, 13511, EGYPT. | ||||
| 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. | ||||
| Keywords | ||||
| FSW; dissimilar aluminum; rotation speed; tool wear; Temperature; UTS | ||||
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