Parametric Optimization of FSWed Dissimilar Composite Joints of AA7075 and AA6061 Using RSM

In the current work, SiC particles-based friction stir welded composite joints of AA7075 and AA6061 were developed. The effects of processing variables (rotating speed, transverse speed and volume percentage of SiC microparticles) on the mechanical characteristics (tensile strength, microhardness and %strain) of the composite joints were examined using response surface methodology. The developed models showed that the rotating speed is the most influential parameter, the volume percentage of SiCp is the second most influential parameter, and the transverse speed is the least influential parameter. The highest tensile strength of 261 MPa, %strain of 32.4% and microhardness of 187 HV were found at rotating speed of 1100 rpm, transverse speed of 40 mm/min and 10% volume percentage of SiC particles. The optimized processing variables, including rotating speed, transverse speed and volume percentage of SiC particles, were found to be 1094 rpm, 40 mm/min and 6%, respectively. The value of multi-optimized output responses, including tensile strength, %strain and microhardness, was found to be 247 MPa, 26.9% and 176 HV, respectively.