Development and Optimization of a Mathematical Model for Predicting Tensile Strength in Friction Stir Welded Joints of 6082-T6 Aluminum Alloy

Abstract

Friction Stir Welding (FSW) is a solid-state joining process that uses a rotating tool to generate heat through friction with the material, causing it to soften without reaching the melting point, thus allowing the parts to be securely joined. This technique is particularly significant in industries requiring high mechanical properties, such as applications involving 6082-T6 aluminum alloy. Given the growing industrial importance of this alloy, there is a need to thoroughly investigate the effects of various welding parameters on the mechanica properties of the resulting weld joints. This study aims to develop a mathematical model to analyze the impact of key welding parameters, including spindle speed, welding speed, shoulder penetration depth, and shoulder profile, on the tensile strength of welded joints. The model was constructed using Response Surface Methodology (RSM), providing a means to predict mechanical performance and optimize process variables. The experimental results showed good agreement with the proposed model, with deviations remaining within acceptable limits, thereby demonstrating the model's potential as an effective tool for improving weld quality in industrial applications.