Numerical Analysis of Fusion Welding of Aluminium Alloys AA5083 and AA6061

Anant Bhardwaj; Sanjay Kumawat; Arun Kumar G.; Aditi D. Raval; Dheeravath Raju; Sahil Suri

doi:10.5750/ijme.v168iA3(S).1971

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Published: Oct 7, 2026

DOI: https://doi.org/10.5750/ijme.v168iA3(S).1971

Keywords:

Friction stir welding Hardness Response surface methodology Tool pin profile Aluminium alloy

Anant Bhardwaj

Mechanical Engineering Department, Delhi Technological University, Delhi, India

Sanjay Kumawat

Poornima College of Engineering, Jaipur, Rajasthan, India

G. Arun Kumar

Professor, Department of Mechanical Engineering, Sathyabama Institute of Science and Technology, Chennai, Tamil Nadu, India

Aditi D. Raval

Assistant Professor, Faculty of Pharmacy, Gokul Global University, Sidhpur, Gujarat, India

Dheeravath Raju

Centre for Multidisciplinary Research, Anurag University, Hyderabad, Telangana, India

Sahil Suri

Centre of Research Impact and Outcome, Chitkara University, Rajpura, 140417, Punjab, India

Abstract

Because of its exceptional corrosion resistance in saltwater and high strength-to-weight ratio, AA5083 and AA6061 arefrequently utilized in maritime applications. Both AA5083 and AA6061 are common choices in the maritime sector, with AA5083 being utilized for hull construction and AA6061 for specific structural elements and marine fittings. One of the most well-known solid-state welding methods for extremely delicate materials like aluminium alloy is friction stir welding (FSW). Aluminium alloys AA5083 and AA6061 are extremely difficult and dangerous to fuse together. FSW takes into account several input process parameters that have a substantial impact on the prepared butt joint hardness. Thus, utilizing a soft computing technique, the study seeks to determine the important input factors and optimize their impact on the constructed butt joints’ hardness. The test specimens are prepared in accordance with American Society for Testing and Materials (ASTM) standard E18-15. Two optimization technique mainly the ANN (Artificial Neural network) and the RSM (Response surface methodology is utilized in obtaining the results. The relationship between input parameters and the desired outcome is discussed using three-dimensional (3D) response surface graphs. The three different shape of the pin, rotational speed of the pin and the welding speed is taken as the input parameters and the hardness is taken as the output parameters. With a hexagon tool pin profile and a rotational speed of 1300 rpm and a welding speed of 30 mm/minute, the Rockwell hardness testing device yielded a maximum value of 67 HRB for the tested specimens, measuring a maximum hardness of 68 HRB.

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Vol. 168 No. A3(S) (2026): Special Issue - Smart and Sustainable Material for Marine Engineering Applications

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