Process Parameters Optimization in Friction Stir Welding of AA2024 and AA6061 Dissimilar Metal Using Fractional Factorial Design

  • Bhargav C. PatelEmail author
  • Akash B. Chovatiya
  • Lalaji N. Godhani
Conference paper


Friction stir welding technique has been used to join AA2024 and AA6061 dissimilar 6 mm thick plate. FSW gives a new trend in dissimilar metal joining process. In addition to joining of aluminium alloys, FSW is used for joining of other materials like steels, polymer etc. Tool rotational speed, welding speed and tilt angle of a tool at three different levels were considered as process parameters. Here, the Fractional factorial design was used to find out the optimum process parameter. With analysis and experimentation, it has been observed that there has been the main effect of tool rotational speed, welding speed and tilt angle on strength of the joint for Aluminium AA2024 and AA6061. In this research paper, percentage contributions from each parameter were computed through which optimal parameters were identified for Aluminum AA2024 and AA6061 plates. Optimum values of tool rotation speed, welding speed, and tilt angle were found out in order to obtain the perfect increased strength of weld joint.


Friction stir welding AA2024 AA6061 Dissimilar welding Fractional factorial design 


  1. 1.
    Nandan R, Roy TD, Bhadeshia HKDH (2008) Recent advances in friction-stir welding – process, weldment structure and properties. Prog Mater Sci Elsevıer 53:980–1023CrossRefGoogle Scholar
  2. 2.
    Khan NZ, Siddiquee AN, Khan ZA, Mukhopadhyay AK (2017) Mechanical and microstructural behavior of friction stir welded similar and dissimilar sheets of AA2219 and AA7475 aluminum alloys. J Alloys Compd 695:2902–2908CrossRefGoogle Scholar
  3. 3.
    Cho JH, Boyce DE, Dawson PR (2005) Modeling strain hardening and texture evolution in friction stir welding of stainless steel. Mater Sci Eng A 398:146–163CrossRefGoogle Scholar
  4. 4.
    Saad Ahmed Khodir, Toshiya Shibayanagi (2007) Microstructure and mechanical properties of friction stir welded dissimilar aluminum joints of AA2024-T3 and AA7075-T6. Joining and Welding Research Institute, Osaka University, Ibaraki, Japan 48(7):1928–1937Google Scholar
  5. 5.
    Sadeesh P, Venkatesh Kannan M, Rajkumar V, Avinash P, Arivazhagan N, Devendranath Ramkumar K, Narayanan S (2014) Studies on friction stir welding of AA2024 and AA6061 dissimilar metals. Int Conf Mater Adv Technol 75:145–149Google Scholar
  6. 6.
    Ilangovan M, Boopathy SR, Balasubramanian V (2015) Microstructure and tensile properties of friction stir welded dissimilar AA606-AA5086 aluminium alloy joints. Trans Nonferrous Metals Soc China Elsevier 25:1080–1090CrossRefGoogle Scholar
  7. 7.
    Somasekharan AC, Murr LE (2004) Microstructures in friction-stir welded dissimilar magnesium alloys and magnesium alloys to 6061-T6 aluminum alloy. Mater Charact Elsevier 52:49–64CrossRefGoogle Scholar
  8. 8.
    Patel BC, Chovatiya AB, Patel UM (2018) Influence of tool design on the mechanical properties in friction stir welding of aluminium HE30 (AA6082). Int J Sci Res Rev 7(6):777–786Google Scholar
  9. 9.
    Patel BC, Gandhi J (2013) Optimizing and analysis of parameter for pipe welding: a literature review. Int J Eng Res Technol 2(10):229–234Google Scholar

Copyright information

© Springer Nature Switzerland AG 2020

Authors and Affiliations

  • Bhargav C. Patel
    • 1
    Email author
  • Akash B. Chovatiya
    • 1
  • Lalaji N. Godhani
    • 1
  1. 1.Chhotubhai Gopalbhai Patel Institute of TechnologyUka Tarsadia UniversitySuratIndia

Personalised recommendations