OPTIMIZATION OF FRICTION STIR WELDING PROCESSING PARAMETERS BY SKH-57 TOOLS STEEL OF SS400-AL6063

The objective of this study’s research was to determine the optimal tools and friction stir welding process parameters of dissimilar material between carbon steel SS400. Which is a material widely used in various industries, including shipbuilding and automotive assembly, and aluminum alloy 6063. Which is a lightweight material. These two materials differ physically and in their mechanical properties with significantly different hardness levels. The maximum tensile strength using the design of experiment technique. This study’s research in four welding parameters consisted of two shapes of shoulder and pin (spiral shape pin with curved surface shoulder and spiral shape pin with flat surface shoulder), Tools rotational speed (500, 550, 600, and 650 rpm), Traverse speed (20, 30, 40, and 50 mm/min), and Tilt angle (0, 1, 2, and 3 degrees). From the experimental results, the welding conditions of the average maximum tensile strength of 189.33 MPa were a spiral-shaped pin with a curved surface shoulder, a rotational speed of 600 rpm, a traverse speed of 50 mm/min, and a Tilt angle of 3 degrees. In addition, the statistical analytical result indicated that the tool’s rotational speed was the most significant factor, and the predicted optimal conditions were a spiral-shaped pin with a curved surface shoulder, a rotational speed of 590 rpm, a traverse speed of 40 mm/min, and a tool tilt angle of 3 degrees. Optimal results had been verified through confirmation experiments with a tensile strength of 191 MPa.