Prediction and optimization of process parameter of friction stir welded AA5083-H111 aluminum alloy using response surface methodology

A systematic approach was presented to develop the empirical model for predicting the ultimate tensile strength of AA5083-H111 aluminum alloy which is widely used in ship building industry by incorporating friction stir welding (FSW) process parameters such as tool rotational speed, welding speed, and axial force. FSW was carried out considering three-factor five-level central composite rotatable design with full replications technique. Response surface methodology (RSM) was applied to developing linear regression model for establishing the relationship between the FSW process parameters and ultimate tensile strength. Analysis of variance (ANOVA) technique was used to check the adequacy of the developed model. The FSW process parameters were also optimized using response surface methodology (RSM) to maximize the ultimate tensile strength. The joint welded at a tool rotational speed of 1 000 r/min, a welding speed of 69 mm/min and an axial force of 1.33 t exhibits higher tensile strength compared with other joints.