Optimization of friction stir welding process to maximize tensile strength of AA6061/ZrB2 in-situ composite butt joints

A variety of ceramic particles is added to aluminum alloys to produce aluminum matrix composites (AMCs). Establishing the joining procedure for AMCs is an essential requirement prior to extending their applications. Friction stir welding (FSW) is an emerging solid state welding which eliminates all the defects associated with fusion welding of AMCs. An attempt has been made to friction stir weld AA6061/ ZrB2 in-situ composite. A four factor, five level central composite rotatable design has been used to minimize the number of experiments. The four factors considered are tool rotational speed, welding speed, axial force and weight percentage of ZrB2. A mathematical model has been developed incorporating the FSW process parameters to predict the ultimate tensile strength (UTS) and FS process is optimized using generalized reduced gradient method (GRG) to maximize the UTS. The effect of process parameters on UTS was analyzed. It was observed that the process parameters independently influence the UTS over the entire range studied in this work.