Optimization of friction stir welding process parameters to maximize tensile strength of stir cast AA6061-T6/AlNp composite

• AA6061/AlNp cast composite was welded by FSW process.
• Regression models were developed to predict UTS and elongation of the FS welded joint.
• FS welded joint using the optimized parameters exhibited maximum UTS and joint efficiency.
• Defect free weld joint was obtained with optimized parameters value.

Aluminium Matrix Composites (AMCs) reinforced with particulate form of reinforcement has replaced monolithic alloys in many engineering industries due to its superior mechanical properties and tailorable thermal and electrical properties. As aluminium nitride (AlN) has high specific strength, high thermal conductivity, high electrical resistivity, low dielectric constant, low coefficient of thermal expansion and good compatibility with aluminium alloy, Al/AlN composite is extensively used in electronic packaging industries. Joining of AMCs is unavoidable in many engineering applications. Friction Stir Welding (FSW) is one of the most suitable welding process to weld the AMCs reinforced with particulate form of ceramics without deteriorating its superior mechanical properties. An attempt has been made to develop regression models to predict the Ultimate Tensile Strength (UTS) and Percent Elongation (PE) of the friction stir welded AA6061 matrix composite reinforced with aluminium nitride particles (AlNp) by correlating the significant parameters such as tool rotational speed, welding speed, axial force and percentage of AlNp reinforcement in the AA6061 matrix. Statistical software SYSTAT 12 and statistical tools such as analysis of variance (ANOVA) and student’s t test, have been used to validate the developed models. It was observed from the investigation that these factors independently influenced the UTS and PE of the friction stir welded composite joints. The developed regression models were optimized to maximize UTS of friction stir welded AA6061/AlNp composite joints.

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