Optimization of Friction Stir Spot Welding Process Parameters of Dissimilar Al 5083 and C 10100 Joints Using Response Surface Methodology¹

Abstract—Using response surface methodology, optimization of friction stir spot welding process parameters of dissimilar Al 5083 and C 10100 joints were experimented. The predominant requirement was to obtain reduced interface hardness and increased tensile shear failure load. For specification of experimental conditions, central composite design matrix was used, with three factors and five levels. With Al 5083 alloy and C 10100 copper twenty joints were made. Experimentally, tensile shear failure load and interface hardness were measured. Significant main parameters and interaction process parameters were evaluated using analysis of variance (ANOVA) method. Regression analysis was used for development of empirical relationship. Design expert software was used for optimization of friction stir spot welding process parameters by using response graphs and constructing contour plots. At 95% confidence level, prediction of tensile shear failure load and interface hardness of the dissimilar Al 5083—C 10100 joints were done using the empirical relations that were developed. The optimum conditions of Al 5083—C 10100 joints by friction stir spot welding process were evaluated using contour plots.