The Optimum Process Parameter of Dissimilar Metal AA6061 – AISI304 Continuous Drive Friction Welding

Abstract

This article explains the use of the response surface method to produce the optimum tensile strength for the joining of dissimilar metals with the continuous drive friction welding method. The joining of dissimilar metals is one of the biggest challenges in providing industrial applications. Continuous drive friction welding has been extensively used as one of the important solid-state welding processes. In this study, the optimization of the friction welding process parameters is established to achieve the maximum tensile strength in AA6061 and AISI304 dissimilar joints via the response surface methodology. The effect of continuous drive friction welding parameters, which are friction pressure, friction time, upset pressure, and upset time, are investigated using response surface analysis. The design matrix factors are set as 27 experiments based on Box-Behnken. The 3D surface and the contour is plotted for this model to accomplish the tensile strength optimization. The optimization model of the tensile strength was verified by conducting experiments on the optimum values of the parameters based on the experimental data results. It can be denoted that the optimum process parameters settings were friction pressure = 25 MPa, friction time = 6 seconds, upset pressure = 140 MPa, and upset time = 8 seconds, which would result in a maximum tensile strength of 228.57 MPa.