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On the tensile characteristics, microhardness, microstructure, and formability of tailor-welded blanks of aluminium alloys (AA) 6082-O and AA5083-O were explored in this study. The influence of these process parameters on Friction stir welded (FSWed) regions such as the weld nugget zone (WNZ), thermomechanical affected zone (TMAZ), and the heat-affected zone (HAZ) has been studied. Response surface methodology (RSM) was utilised to investigate the impact of process factors. Using four components and three levels, 30 trials were run. There is a direct correlation between FSW input process parameters and output responses such as tensile strength, yield strength, elongation, microhardness value and dome height. The constructed model is tested for appropriateness using ANOVA technique. The experimental and predicted findings were well correlated. Scanning electron microscopy (SEM) was used to evaluate the microstructure of the friction stir welded regions such as WNZ, TMAZ, and HAZ. The maximum hardness was achieved at 4 mm pin diameter with all rotational speed due to finer grain structure formed at WNZ region. The experimental and optimised values were compared and agreed.

Effect of high tool rotational speed and pin diameter on mechanical properties, microstructure and formability of friction stir tailor welded blanks