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In the present work, joining of dissimilar aluminum alloys AA6061 and AA8011 was carried out by FSW butt joint. The Taguchi L 9  orthogonal array design of experiments was adopted for the experiments to estimate optimal process parameters such as rotational speed, welding speed and axial force using Minitab 18. In ANOVA analysis, the priority of input parameters and the contribution percentage of each factor were determined through response and analysis of variance tables. From the ANOVA analysis data, tensile strength, impact strength and hardness of substantial values were optimized. Further thermal analyses of optimized values were examined through COMSOL Multiphysics 5.3b model which also successfully predicted the maximum welding temperature obtained from pin and work piece interaction of each position during welding. In this investigation the transient temperature levels of the weld zone during welding and after welding were investigated. Likewise the curves of transient temperatures were plotted with the aid of Origin Pro 2018.

Optimization and thermal analysis of friction stir welding of AA 6061-AA 8011 joints