Title: Optimisation and sensitivity analysis of friction stir welding process and tool parameters for joining AA1100 aluminium alloy

Authors: S. Rajakumar, C. Muralidharan, V. Balasubramanian

Addresses: Center for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar – 608 002, Chidambaram, Tamil Nadu, India. ' Department of Manufacturing Engineering, Annamalai University, Annamalainagar – 608 002, Chidambaram, Tamil Nadu, India. ' Center for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar – 608 002, Chidambaram, Tamil Nadu, India

Abstract: This paper focuses on the development of empirical relationship for the prediction of tensile strength of friction stir welded AA 1100 aluminium alloy joints. The experimental part of the study is based on five level central composite designs of six (process and tool) parameters. Optimisation of the model is carried out to maximise the tensile strength using design-expert software. A sensitivity analysis is carried out and compared the relative impact of input parameters on tensile strength in order to verify the measurement errors on the values of the uncertainty in estimated parameters. The results obtained show that developed empirical relationship can be applied to estimate the effectiveness of process and tool parameters for a given tensile strength. The rotational speed is more sensitive than tool hardness, followed by axial force, shoulder diameter, pin diameter and welding speed.

Keywords: friction stir welding; FSW; central composite design; CCD; response surface methodology; RSM; optimisation; sensitivity analysis; aluminium alloys; tensile strength; process parameters; tool parameters; rotational speed; tool hardness; axial force; shoulder diameter; pin diameter; welding speed.

DOI: 10.1504/IJMMP.2011.040442

International Journal of Microstructure and Materials Properties, 2011 Vol.6 No.1/2, pp.132 - 156

Published online: 27 May 2011 *

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