Optimization of Mechanical Properties of Friction Stir Spot Welded Joints for Dissimilar Aluminum Alloys (AA2024-T3 and AA 5754-H114)

Abstract

In this work, friction stir spot welding (FSSW) was performed for dissimilar aluminum alloys (AA2024-T3 and AA5754-H114) sheets of 2 mm thick at different tool rotational speeds (800, 1000 and 1250 rpm), plunging times (30, 60 and 90 s) and tool pin profile or geometry (threaded cylindrical with flute, tapered cylindrical and straight cylindrical). Process parameters were optimized by using Taguchi technique and depending on design of experiment (DOE), and data analysis based on the Taguchi method is performed by utilizing the Minitab 17 to estimate the significant factors of the FSSW and main effects using few experimental tests only. It was found that maximum shear force was (2860 N) obtained at best welding process parameters: 800 rpm of rotation speed, 60 s of plunging time and taper cylindrical pin which are obtained from the DOE. Pareto chart of the standardized effects of tensile shear results showed that the pin profile was the most effective parameter than other welding parameters (rotation speed and plunging time). Also it was found that the contribution percentage was 61.5% for pin profile followed by tool rotation speed 20.1% and plunging time 18.4%.