Experimental modeling and the effect analysis of friction stir welding parameters of 5456 aluminum alloy using response surface method

Friction stir welding is a solid state process which is developed by Twi institute in 1991. In this paper، lap welding of 5456 aluminum alloy sheets were carried out while hard working H321 sheet with a thickness of 5 mm was on top of a 2. 5 mm thickness annealed sheet and the simultaneous effect of rotation speed of tool، feed rate and tool angle parameters on failure force and the height of hook in friction stir welding were investigated using response surface method. After evaluation and analysis of welding samples، response surface method was used using experimental results and several verification models were performed for error estimation. The results of mechanical properties of model show 3. 88 percent average error with experimental results. In proceeding، the analysis of variance was used for investigation of the welding parameters effect on welding mode variations and it was seen that feed rate has the greatest effect on failure force and rotation speed has the greatest effect on the hook height and tool angle has the lowest effect in comparison with this two parameters.