Optimization of Tensile and Corrosion Properties of Dissimilar Friction Stir Welded AA2024-7075 Joints

In this work, we performed some joining experiments of dissimilar aluminum alloys AA2024-T351 and AA7075-T651 using friction stir welding (FSW) technique with different process parameters (rotational speed, welding speed and plunge depth). Response surface methodology based on a central composite rotatable design was used to establish the mathematical models predicting the tensile properties and corrosion rate of dissimilar FSW joints with some high confidence level. Analysis of variance method was employed to verify the developed models. Besides, the influences of FSW process parameters on tensile and corrosion properties of joints were analyzed. In order to obtain a desirable combination property of the dissimilar FSW joints, the optimum process parameters after experimental verification were proposed as: rotational speed 1495rev/min, welding speed 187mm/min and plunge depth 0.03mm. This verification illustrated that the developed models are appropriate for the modeling and optimization of process.