International Journal for Research in Technological Studies| Vol.
2, Issue 12, November 2015 | ISSN (online): 2348-1439
Optimization of Process Parameters of Friction Stir Welding for
Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
Mr.Anil S Kumar1 Mr.R.Mahesh Rengaraj2
1
M.Tech Student 2Associate Professor
1,2
Department of Production and Industrial Engineering
1,2
SCMS school of Engineering and Technology, MGU, Ernakulam
Abstract— In this investigation, dissimilar aluminium alloy
AA5083-O and 6061-T6 has been joined with the help of
friction stir welding. Response surface methodology based
central composite rotatable design with 20runs, 3
parameters (Tool rotational speed, Traversing speed and
axial load), 5 level was used in developing a mathematical
model which predict the material properties like ultimate
tensile strength and percentage elongation .Analysis of
variance was used to validate the model. Optimum process
parameter settings for getting maximum tensile strength
were found out to be tool rotational speed of 1368rpm,
traversing speed of 44mm/min, and axial load of 6.4kN,
whereas for maximum percentage elongation process
parameter setting were tool rotation speed of 1500rpm,
traversing speed of 44mm/min and axial load of 6.6Kn
.Confirmation test was also carried out. Effect of each
process parameter on the response was also illustrated in
this paper.
Keywords— Response Surface Methodology, Optimization,
Dissimilar Aluminium Alloys, Mathematical Modeling,
Central Composite Design
I. INTRODUCTION
Friction stir welding is a solid-state joining process which
was invented at The Welding Institute (TWI), Cambridge
(UK)[1].Friction stir welding uses a non-consumable
rotating tool with a profiled pin and a shoulder design .This
profiled pin is inserted to the abutting surface to be joined
and moved along the line of joint to be welded[[2]-[5]].Due
to the friction between the rotating tool and workpiece
frictional heat is developed which soften the area of the
material around the pin. Combined action of tool rotation
and translation cause the material to flow from the front to
backend of the pin which results in welded joint
[4].Compared to conventional welding friction stir welding
has metallurgical benefits, energy benefits and
environmental benefits. Metallurgical benefits include
excellent mechanical properties along the joint area, good
dimensional stability, fine recrystallized microstructure,
absence of solidification cracking etc whereas
environmental benefits include absence of harmful gases
,shielding gases and does not require any consumable
materials [7].Compared to laser welding friction stir welding
require relatively low energy[7] . The 5series aluminium
alloys constitute of group of non-heat treatable alloys with
high ductility, medium strength and very good corrosion
resistance. Due to these excellent properties, 5series
aluminium alloys are extensively used in automotive parts,
marine applications and in construction industries. In 6
series aluminium alloys, major alloying elements are silicon
and magnesium. The 6series aluminium alloys are used in
the fabrication of lightweight structures. They are high
strength aluminium alloys which have excellent welding
characteristics due to which they are used extensively in
marine industries, aircraft industries and for making
pipelines and storage tanks.
It was found that process parameters like tool
rotation, traversing speed and axial load are the important
parameters which determine the mechanical properties of
the weld(2-5). The present investigation focuses on
developing a mathematical model which could predict the
mechanical properties like tensile strength and percentage
elongation. Response surface methodology was used to
optimise the process parameters for achieve best possible
mechanical properties (tensile strength and elongation).
Response surface methodology is the method which is
adopted for modelling and optimizing the process
parameters of fsw. The response surface is a collection of
statistical and mathematical method which was developed
by Box and Wilson, which are extensively use in modelling
and analysing the engineering problems [8,13].
Rsm has been deployed to predict the properties of
friction stir welded aluminium joints[1-7,14]. A.
Heidarzadeh et al developed a mathematical model with the
help of RSM which predicts the tensile strength and tensile
elongation of friction stir welded joints of aluminium
AA6061-T6 alloy[3]. G. Elatharasan et al used rsm in order
to create a mathematical relationship between friction stir
process parameter (traversing speed, axial load and
rotational speed) and its mechanical properties of friction
stir welded joints of AA6061-T6 alloys[4]. Huijie Liu
developed a predicting model and optimized the process
parameter for underwater friction stir welding of heat
treatable aluminium alloy[9]. S. Rajakumar et al used RSM
to develop an empirical relationship between mechanical
properties of aluminium alloys and they found out optimum
process parameters for ultimate tensile strength[2].
Kadaganchi R et al.[10] published a paper which
focused on optimizing the process parameters of friction stir
welded AA2014-T6 aluminium alloy using response surface
methodology. This was used for developing a mathematical
models which could predict ultimate tensile strength, yield
strength and percentage elongation .The result indicates the
effect various process parameters on tensile strength, yield
strength and percentage elongation.
II. EXPERIMENTAL WORK
Aluminium alloys 5083-O and 6061- T6 were made into
small plates of dimensions 100X50X5 mm by using a shear
cutting machine. In order to have a better finish at the edges,
materials were smoothened with the help of a super mill
milling machine. Mechanical clamps were used to secure
material plates in proper position. Single pass friction stir
welding perpendicular to the direction of rolling plate is
used to fabricate the joint. From previous literature, the main
parameters which have the paramount influence on material
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 Optimization of Process Parameters of Friction Stir Welding for Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
(IJRTS/Vol. 2/Issue 12/Nov. 2015)

properties of aluminium alloys were identified as tool

rotation, axial load and traversing speed([2]-[5],[1]2). The
non-consumable tool of cylindrical profile was employed to
fabricate the joints of aluminium alloys. The tool has a
shoulder diameter of 18mm, probe length of 4.7mm and
probe diameter of 5mm. A large number of trial runs were
carried out in order to set the working range of input
parameters .Feasible limit was set in such a way that welded
joints should be free from any macro defects. Important Fig. 2: Tensile specimen nomenclature
process parameters that have a strong influence on material All values in mm Flat test specimen
properties and its working range are shown in table 1. Gauge length 25
Factor Units Factor level Width 6
-1.68 -1 0 1 1.68 Thickness 6
Tool Fillet radius 6
Rpm 1097. 120 135 150 1602.
rotational Overall length 100
(N) 7 0 0 0 3
speed Length of reduced section 32
Traversin mm/mi Length of grip section 30
23.1 30 40 50 56.8
g speed n (S) Width of grip section 10
Axial
kN(F) 5.3 6 7 8 8.7 Table 2: Specimen Specification
force
Table 1: FSW process parameters and their levels
III. DEVELOPING THE MATHEMATICAL MODEL
In the present study, central composite rotatable
design matrix with 20 runs, three factors and five level was A. Response Surface Methodology
employed inorder to optimise the experimental process The response surface is a collection of statistical and
parameter. The coded value for any intermediate level can mathematical method used for analysing complex
be found out by substituting the value in the below equation. engineering problems. Response surface methodology is
Xi = 2[2X –(Xmax + Xmin)]/[Xmax – Xmin] used for optimising the process parameters. Further, it
Where Xi is the required coded value of a variable establishes a mathematical regression model which could
X and X is any value of the variable between Xmax and predict the relationship between response and independent
Xmin. variables (process parameters). This mathematical model is
Where used to predict the response when we changes the process
 Xi is the required coded value of a variable X parameters within the range. Geometrically, regression
 X is any value of the variable from Xmin to Xmax model represent a surface and can be plotted as response
 Xmin is the lower level of the variable versus any of the two parameter. Such plots help in
 Xmax is the highest level of the variable. visualising the effect of process parameters on response
.Response plot and contour plot helps in visualising the
optimum process parameter for the response.
The response properties of the Friction Stir welded
joints are a function of rotational speed (A), traversing speed
(B) and axial force (C). The response surface can be
expressed as follows:
Z =f(A,B,C)
The second order polynomial equation was used to
represent the response surface ‗Z‘ is given by
Z = bO + ∑bixi + ∑bijxi2 +∑bijxixj+ er
where bO represent the intercept term, bi represent
the linear term, bii represent the quadratic term and bij
represent the interaction term. Design expert software was
Fig 1: Cylindrical Tool Profile used to develop the model and developed model is shown
Welded joints were fabricated as per the American below.
Society for Testing of Materials (ASTM E8M-04) standards Final model developed is given by
to assess the tensile strength of the welded material  Ultimate tensile strength ( UTS ) =219.658 +
joints[11]. Tensile testing was then carried out in universal 5.06536 * A + 4.69023 * B + -3.418 * C + -7.625 *
testing machine and its result is shown in Table 3. AB + -4.375 * AC + -10.375 * BC + -18.4671 *
A^2 + -11.8718 * B^2 + -6.8573 * C^2
 % Elongation = 12.4552 + 1.22708 * A + -
0.223345 * B + 0.171263 * C + -0.1 * AB + -0.175
* AC + 0.1 * BC + 0.134468 * A^2 + -0.00678002
* B^2 + -0.127046 * C^2
Design expert software was used for estimating the
all the coefficient and tested using f-test at 95 % confidence

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 Optimization of Process Parameters of Friction Stir Welding for Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
(IJRTS/Vol. 2/Issue 12/Nov. 2015)

No Input parameters Output response B. Checking for Adequacy of Model

Std A B C UTS %Elongation
rpm mm/min KN MPa
1 1200 30 6 155 11
2 1500 30 6 187 14
3 1200 50 6 200 10.6
4 1500 50 6 210 13.4
5 1200 30 8 174 11.3
6 1500 30 8 197 13.8
7 1200 50 8 186 11.5
8 1500 50 8 170 13.4
9 1097.7 40 7 158 11
10 1602.3 40 7 170 14.9
11 1350 23.1 7 179 13.1
12 1350 56.8 7 186 12
13 1350 40 5.3 203 11.8
14 1350 40 8.7 190 12.6
15 1350 40 7 216 12.5
16 1350 40 7 218 12.4
17 1350 40 7 220 12.2 Table 4: ANOVA result for the response ultimate tensile
18 1350 40 7 225 12.4 strength
19 1350 40 7 217 12.5
20 1350 40 7 223 12.7
` Table 3: Design matrix with responses (mechanical
properties of welds)

Fig 3: Photograph of tensile specimen after testing

Table 5: ANOVA result for the response % elongation

Adequacy of the developed model was checked
using ANOVA technique. Table 4 and Table 5 shows the
result of anova for the models(UTS and percentage
elongation). It can be seen that calculated f ratio is less than
the standard f ratio ( from f table ) at 95% deserved level of
confidence. Which indicate that the models are adequate.
The coefficient of determination (r2 ) shows the goodness of
fit for the developed model. Higher the value of r2 better the
model in predicting the response. The difference between r 2
and adjusted r2 is less than 2 % which indicate that the
model is not over fitted. The adjusted R2 value is high,
which points out high significance of the model. Value of
adequate precision was found to be good which gives a
justifiable performance in prediction. Usually, a value

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 Optimization of Process Parameters of Friction Stir Welding for Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
(IJRTS/Vol. 2/Issue 12/Nov. 2015)

greater than 4 is suitable. It is also desirable to have

relatively low value for coefficient of variation, as lower
coefficient of variation signifies a good reliability of
conducted experiment and high degree of precision. It is
suitable to have a lower value for ‗PRESS‘ as it indicates
how well the model is likely to predict the response in a new
experiment. Normal plots for residuals for both tensile
strength and percentage elongation fall along a straight line
which says that the errors are normally distributed.

Fig 5: Normal plot for residuals for: a(UTS) and

b(percentage elongation)
C. Optimizing the Process Parameters
In order to determine optimum process parameter contour
plot and response plot were used. Counter plot and response
plot are plotted for each response vs any two process
parameter, while keeping the other parameter at middle
level. Counter plot and response plot gives a visual region of
optimum settings. Counter and response plot play an
important role in identifying optimum factor settings.
Design expert software was used for identifying the
optimum factor settings for maximum mechanical
properties. The optimum process parameters for maximum
tensile strength were found out to be tool rotation speed of
1368rpm, traversing speed of 44mm/min and axial load of
6.4kN and for maximum percentage elongation, optimum
process parameter settings were found out to be rotational
speed of 1500 rpm, Traversing speed of 30 mm/min and
axial load of 6.6kN.

Fig. 4: Plot of predicted response vs actual value for: (a)

UTS and (b) % elongation

Fig 6: Contour plot showing optimum factor setting for UTS

Copyright© IJRTS | www.ijrts.com 11


Design-Expert® Software
Factor Coding: Actual
%ELONGATION
14.9
10.6
X1 = A: A(Tool Rotation)
B: B(Traversing Speed) (mm/min)
X2 = B: B(Traversing Speed)
Actual Factor
C: C(Axial Load) = 6.60452
Fig 7: Contour plot showing optimum factor setting for %
elongation.
D. Confirmation Test
Confirmation run was conducted at optimum process
parameter settings. For tensile strength optimum process
parameters were found out to be of rotation speed of
1368rpm, traversing speed of 44mm/min and axial load of
6.4kN and the ultimate tensile strength was found out to be
218Mpa which was well within the limit predicted by the
model. Similarly, percentage elongation was done at
optimum settings and it was also found out to be within the
confidence interval.
IV. RESULTS AND DISCUSSIONS
From mathematical model developed influence of process
parameters on the responses (mechanical properties) is
evaluated. Fig 10 and Fig 11 shows response and counter
plot for response UTS and percentage elongation.
Irrespective of whatever the process parameter is the
ultimate tensile strength of the fabricated joint is always less
than the base metal. Tool rotational speed, welding speed
and axial load have considerable effect on frictional heat
generated and the plastic flow of the material. Effect of tool
rotational speed, traversing speed and axial load are
explained as follows.
Fig 8: Perturbation plot showing the effect of all factors on
ultimate tensile strength
Optimization of Process Parameters of Friction Stir Welding for Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
(IJRTS/Vol. 2/Issue 12/Nov. 2015)
%ELONGATION
50
45
12 13
40
35
Prediction 14.1556
X1 1500 14
X2 30.0001
30
1200 1275 1350 1425 1500 Fig 9: Perturbation plot showing the effect of all factors on
% Elongation
A: A(Tool Rotation) (rpm)
A. Effect of Process Parameter on Ultimate Tensile
Strength
1) Effect of Rotational Speed
It can be seen from the perturbation plot ( fig 8) and counter
plot (fig 10a and 10b) that increase in tool rotational speed
increases the tensile strength up to a point. Further increase
in tool rotation results in decrease in tensile strength of the
friction stir welded joints. At lower tool rotational speed,
friction heat generated is low which results in poor plastic
flow of the materials. Whereas in higher rotational speed
there occurs metallurgical transformation like solubilising,
re-precipitation and lowering of dislocation density which
decrease tensile strength of friction stir welded joints.
2) Effect of Welding Speed
From the perturbation plot (fig 8) and contour plot( fig 10a
and fig 10c) it can be seen that increase in traversing speed
increase the tensile strength of the material up to a point.
The further increase in traversing speed decrease the tensile
strength of friction stirs welded joints. This is because lower
traversing speed increases metallurgical transformation
which results in decrease of tensile strength of friction stir
welded joints. Whereas increase in traversing speed
discourages the clustering effect of strengthening
precipitates and the plastic flow of materials.
3) Effect of Tool Axial Force
From perturbation plot (fig 8) and contour plot (fig 10b and
fig 10c) it can be seen that increase in tool axial force
increase the tensile strength up to a maximum value. Further
increase results in decrease of tensile strength of the friction
stir welded joints. At lower axial force, lower frictional heat
developed as a result lower tensile strength is observed.
Whereas at highest axial force the plunge depth of the
rotating tool on the work piece is higher which results in
lowering of tensile strength along the friction stir welded
joint.
B. Effect of Process Parameters on Percentage Elongation
The perturbation plot for percentage elongation of joints is
shown in fig 9. Counter plot and response plot are shown in
fig 10( d-e) From perturbation ,counter plot and response
plot fig11(d-e) it is evident that the increase in tool rotation
and axial force results in increase in percentage elongation
whereas increase in welding speed results in decrease of
percentage elongation .Increase in tool rotation and axial
force and decrease in welding speed lead to elimination of
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 Optimization of Process Parameters of Friction Stir Welding for Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
(IJRTS/Vol. 2/Issue 12/Nov. 2015)

defects in the weld zone of the joints .This is because of

enough frictional and plastic flow of material .

Fig 10: Shows counter plot showing the effect of any two
process parameter on response (a-c) UTS and(d-f) %
elongation

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 Optimization of Process Parameters of Friction Stir Welding for Dissimilar Aluminium Alloys AA5083-0 and 6061 –T6
Fig 11: Response plot (a-c)UTS and (d-f) Percentage
elongation
V. CONCLUSIONS
From this study, the following important conclusions have
been obtained:
1) Operation range for obtaining high-quality friction
stir welded joints of AA5083-O and AA6061-T6
was obtained.
2) Central composite design was used in developing a
mathematical model which could predict ultimate
tensile strength and percentage elongation of
friction stir welded joints and adequacy of
developed model was also checked .
3) It was found out that increase in tool rotational
speed, traversing speed and axial load increases
ultimate tensile strength up to a maximum value
and further increase results in decrease of ultimate
tensile strength .
4) Percentage elongation of the material increases
with increase in tool rotation speed and axial load
and the decrease in traversing speed.
5) Optimum parameters for maximum tensile strength
were obtained as, tool rotational speed of 1368rpm,
traversing speed of 44mm/min, and axial load of
(IJRTS/Vol. 2/Issue 12/Nov. 2015)
6.4kN and for maximum percentage elongation it
was found out to be, tool rotation speed of
1500rpm, traversing speed of 44mm/min and axial
load of 6.6Kn.
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(IJRTS/Vol. 2/Issue 12/Nov. 2015)

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