Tensile strength prediction of aluminium alloys welded by FSW using response surface methodology – Comparative review

Abstract

Abstract Friction Stir Welding (FSW) process is an invented welding technique where a non-consumable tool uses to join two surfaces. Welding speed, tool rotational speed, axial load, and geometry of the tool consider as key variables in determining the joint s strength in this process. Response Surface Methodology (RSM) is one of the familiar techniques used to optimize the welding parameters. Herein, a comprehensive literature review of using RSM for modelling and optimizing the joint strength has been introduced. This study also examines the presented empirical equations and compare the optimum condition results for the similar and dissimilar alloys. The review indicates that the central composite design matrix with three or four factors is the main method used for RSM. Furthermore, most studies are focused on alloys 1xxx, 6xxx and 2xxx with few studies on 5xxx and 7xxx while there are very limited studies on 3xxx, 4xxx. The optimum tensile strength varies from (73–105) MPa for Al 1xxx series, (219–360) MPa for 2xxx series, (255–294) MPa for 5xxx series, (104–288) MPa for 6xxx series and (319–377) MPa for 7xxx series depending on process parameters.