Optimization of friction stir spot welding parameters of AA6061/Al2O3 using response surface methodology

The use of aluminum alloys is rapidly increasing due to their high strength-to-weight ratio. Friction Stir Spot Welding (FSSW) is a relatively new method that has seen significant growth in recent years for welding materials such as aluminum alloys, magnesium, and steel. This study will investigate the effect of process parameters on the lap shear load of AA6061 sheets with the addition of Al2O3 nanoparticles using friction stir spot welding. Three different process parameters were selected for examination: tool rotational speed, tool plunge depth, and tool dwell time. After the welding process, the samples were subjected to a tensile test, and the obtained results were used to predict the shear tensile load of the samples about the parameters of the friction stir spot welding process using the response surface optimization method. The percentage contribution of the process parameters was predicted using analysis of variance (ANOVA). Experimental results indicated that among the three process parameters, tool rotational speed had the most significant effect on the lap shear load of AA6061/Al2O3. According to the optimization results, the optimal process parameters for friction stir spot welding joints were achieved at a tool rotational speed of 1500 rpm, a tool plunge rate of 20 mm/min, and a tool dwell time of 12 Sec.