Studying the effects of process parameters on the mechanical properties in friction stir welding of Al-SiC composite sheets

Friction stir welding (FSW) was applied to join Al-SiC composite sheets, and the response surface method (RSM) was employed to optimize the effects of traverse speed and rotational rate process parameters on the mechanical properties of welded sheets. Eleven test cases were designed to carry out the FSW process. The mechanical properties of the welded sheets were studied via tensile and microhardness tests. XRD diffraction patterns were also used to obtain residual strains. An RSM analysis was carried out on the results to determine the optimal process parameters and achieve the best mechanical properties for welded composite sheets. The results show that the combined effect of the two parameters played a key role in determining the tensile strength, microhardness, and residual stress and strain of the welded sheets. Optimal mechanical properties were obtained at a rotational rate of 1300 rpm and traverse speed of 70 mm/min.