Optimization of the parameters of low-carbon steel (EN10130) welding using friction stir welding method

Friction-stir welding process is a novel method of solid state welding, which produces heat due to friction between the pin, the shoulder and the workpiece. This heat causes a paste area. Shoulder pressure and pin spin cause edges integration and lead to welding. In this study, firstly, the feasibility of welding of steel sheet (EN10130) with a thickness of 1.5mm has been tested by 58 experiments. After making perfect welds, the ranges of 500-1000 RPM and 30-160 mm/min were selected as the suitable upper and lower levels, respectively, for rotational speed and linear speed. To achieve a maximum tensile strength, 29 tests were designed by using the Box-Benken method considering specified levels of the parameters. Then, the response surface methodology was used for optimization of the parameters. Results showed that the optimal outputs and experimental data were in good agreement, which indicate the adequacy of the design of experiments and optimization predict results. Micro-hardness tests, metallography and normal tensile test were carried out on three series of plates produced with the most appropriate tensile strength and elongation. Results showed that heat-affected zone weaked the sheet of advancing side compared to other welding zones.