Metallurgical Bonding, Interfacial Chemistry, and Mechanical Optimization of Dissimilar AA7079–AA6063 Welds via Response Surface Methodology

This paper aims at establishing the best FSW process parameters during joining AA 7079 and AA 6063 to achieve the strong joint with good mechanical properties.The experiment design used the Taguchi L9 orthogonal array to investigate the FSW parameters of tool rotation speed, axial force, and welding speed.Nine different sets of parameters were used to produce the FSW joints were made, percentage elongation, hardness value, tensile strength and impact strength of the weld joints were studied.The response surface methodology (RSM) is used to find out the interaction between the process factors and mechanical properties.The RSM analysis helps analyze and find the best welding conditions for the AA 7079 with AA 6063.The investigation of the mechanical properties obtained from the joints prepared with the optimized parameters have shown closer agreement with the RSM model thus signifying the potential of this approach in improvement of mechanical properties of dissimilar AA 7079-AA 6063 FSW joints.