Multi-response optimization of FSW

process parameters of dissimilar

aluminum alloys of AA2014 and AA6061
by response surface methodology
(RSM)
Husain Mehdi; Lalit Batra; Abhendra Pratap Singh et al.

2023

The temperature and plastic strain experienced by the material vary

around the SZ due to the Friction stir welding process, which leads to
a heterogeneous microstructure

Abstract
This work aims to establish the mathematical model to predict the hardness, UTS, and %
elongation of the FSW joints of AA6061 and AA2014 using RSM. The experiment was
designed with three factors and three levels, resulting in 20 experimental runs. The model’s
adequacy was checked using analysis of variance at a 95% confidence level, and input
parameters, i.e. Tool tilt angle (TTA), Tool rotational speed (TRS), and welding speed (WS),
and output responses, i.e. hardness, UTS, and % strain were considered. This work
perceived that TRS and WS were the most significant parameters affecting the mechanical
characteristics of the weldments. The maximum UTS (235.76 MPa) and percent strain
(19.35) was achieved at a TRS of 1200 rpm, a WS of 100 mm/min, and a TTA of 2°. On the
other hand, the lowest UTS (136.92 MPa) and microhardness (63 HV) were observed at a
WS of 70 mm/min, a TTA of 2°, and a TRS of 900 rpm. The plastic deformation observed by
the stirring action of the tool, accompanied by the high temperature, leads to the DRX of
grains. The grains are shattered into a refined structure due to the rotation and movement
of the tool during welding. The average grain size for sample numbers 7, 10, 2, and 12 was
observed as 11.56 μm, 9.86 μm, 5.63 μm, and 4.12 μm. The formation of sub-grains was
found to be essential in improving the UTS of FSW joints. The sub-grains can act as
obstacles to dislocation motion and enhance the material’s strength and toughness. The
refined grain structure observed in the stir zone of the FSW weldments of AA2014 and
AA6061 at high rotational tool speeds might be attributed to the mutual effect of high
temperature, DRX, and plastic deformation.
Findings
Furthermore, the results suggest that the UTS can vary on both sides of the weld’s center

Scholarcy Highlights
 Friction stir welding (FSW) has developed as an auspicious solid-state joining
procedure for similar and dissimilar light metal alloys
 The FSW of AA6061 and AA2014 was examined by a threaded pin profile at tool
rotational speeds (TRS) of 500 and 1500 rev/min with a welding speed (WS) of 90 mm-
min-1, and it was perceived that the formation of a large softened zone occurred at the
higher TRS compared to the lower TRS [9]
 The temperature and plastic strain experienced by the material vary around the SZ due
to the FSW process, which leads to a heterogeneous microstructure
 ● The microstructure of the welded joint of AA6061 and AA2014 alloys was found to be
refined and homogeneous, and there was no visible defect in the joint
 ● The temperature and plastic strain experienced by the material vary around the SZ
due to the FSW parameters, which leads to a heterogeneous microstructure
 The results suggest that the ultimate tensile strength (UTS) can vary on both sides of the
weld’s center
 The highest temperature and plastic strain occur in the material close to the SZ, which
results in the DRX and refine grains structure perceived in this region. ● The highest
hardness value (109 HV) was measured at WS of 85 mm-min-1, TRS of 1200 rev/min
with a tilt angle (TTA) of 1°, whereas the least hardness (63 HV) was measured at WS of
70 mm-min-1, TRS of 900 rev/min with a TTA of 2°. ● The output responses UTS, %
strain, and hardness value at SZ, and their observed optimal values are 185.60 MPa,
15.40%, and 85.56 HV, respectively

Scholarcy Summary

Introduction
Friction stir welding (FSW) has developed as an auspicious solid-state joining procedure for
similar and dissimilar light metal alloys.

The inadequate material mixing and input heat during the welding method may lead to the
materialization of various flaws, i.e., voids and tunneling, which can compromise the
ultimate tensile strength (UTS) of the joints

To avoid these challenges, the FSW of AA6061 and AA2014 was examined by a threaded pin
profile at tool rotational speeds (TRS) of 500 and 1500 rev/min with a WS of 90 mm-min-1,
and it was perceived that the formation of a large softened zone occurred at the higher TRS
compared to the lower TRS [9].
Another study was conducted on the FSWed joint of AA7075 and AA6061 with a plate
thickness of 6.1 mm using various tool pin profiles, TRS of 600 to 1800 rev/min, WS of 30 to
130 mmmin-1, and preheat temperature, and they optimize the FSW process parameters to
achieve a high quality welded joint with enhanced mechanical properties [10].

RSM, on the other hand, can accommodate a larger number of parameters and their
interactions, making it suitable for capturing more comprehensive relationships

Objectives
This work aims to establish the mathematical model to predict the hardness, UTS, and %
elongation of the FSW joints of AA6061 and AA2014 using RSM

Methods
The experimental setup for the fabrication of dissimilar AA6061 and AA2014 FSW joints
consisted of a numeric control FSW machine having a rotating spindle, automated process
control table, tool head, and fixture to facilitate the welding process.

The selection of AA6061 and AA2014 for FSW is driven by their similarity in composition,
industrial relevance, different properties, opportunities for joining dissimilar materials, and
existing research interest.

These factors make AA6061 and AA2014 alloys suitable candidates for investigating the
FSW process and understanding its implications for joining these materials.

The process parameter ranges are taken based on trial runs performed and the capacity of
the FSW machine used for welding.

The design of experimentation (DOE) based on three process parameters (TRS, WS, and
TTA) with their three levels were designed by the RSM method.

The other parameters were taken constant, with the tool pin position at the center of the
weld line

Results
Results and discussion3.1 Microstructure analysisMicrostructure observation is an essential
technique employed during FSW to detect various defects such as pinholes, tunneling
defects, and fractures, among others.

The 3rd element is plasticized hot forging by the tool shoulder.

These elements combine to form a strong, reliable welded joint.

Improper adjustment of the parameters during FSW can result in defective joints.

The mixing and penetration of the two alloys are intense in this region, and the plasticized
material undergoes extreme superplastic flow, leading to tumultuous intercalation patterns.
The stirring tool action causes both alloys to undergo in-situ extrusion and intense plastic
deformation, and the plasticized material is transported layer by layer, creating a lamellae
structure.

Observations of the macrostructure and microstructure in this region provide insights into
the FSW parameters’ behavior and assistance identifying potential defects [25]

Conclusion
This work investigated the optimization of FSW process parameters for joining two
differents (AA2014and AA6061) using RSM and observed the following conclusions. ● The
base plates (6.2 mm) of AA6061 and AA2014 were successfully fabricated via FSW.

The optimal values of WS, TRS, and TTA have been mentioned, which are 70.62 mm-min-1,
1148.92 rev/min, and 1.9°, respectively

Contributions
This work investigated the optimization of FSW process parameters for joining two
differents (AA2014