Design Optimization and Experimental Investigation on Friction Stir Welded Aluminium Alloys and its Mechanical Characteristics

Aluminium alloy, boasting a comparable strength-to-weight ratio and light weight material, presents itself as a feasible alternative to Steel. To overcome the challenge of welding aluminium, friction stir welding (FSW) is employed. This study aims to pinpoint the most effective optimization strategy for FSW settings, with a focus on variables such as rotation speed, weld feed, axial force and tool design. Tensile, flexural, wear, corrosion and impact tests are conducted on welded samples to ascertain optimal ultimate tensile strength, maximum yield strength, elongation and impact resistance.