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.