Abstract:Friction welding (FW) is a process of solid state joining which is used extensively in recent years due to its advantages such as low heat input, production efficiency, ease of manufacture and environment friendliness. Friction welding can be used to join different types of ferrous metals and non-ferrous metals that cannot be welded by traditional fusion welding processes. The process parameters such as friction pressure, forging force, friction time and forging time play the major roles in determining the strength of the joints. In this investigation an attempt was made to develop an empirical relationship to predict the tensile strength of friction welded AA 6082 aluminium alloy and AISI 304 austenitic stainless steels joints, incorporating above said parameters. Response surface methodology (RSM) was applied to optimizing the friction welding process parameters to attain the maximum tensile strength of the joint.

Key words: friction welding; aluminium alloy; stainless steel; response surface methodology; optimization