Author: Abolfazl Mahyapour Lori (Engineering and Design Unit Expert)

This article utilizes the response surface methodology (RSM) to model the tensile strength of composite metal sheets using the friction stir processing (FSP) method. The base metal used is 1100 aluminum alloy, and the additive material is aluminum oxide powder. A total of 20 experiments were designed based on process input parameters, including tool rotational speed, tool feed rate, and additive powder weight. After conducting the experiments, the tensile strength results for the composite samples were extracted and analyzed using ANOVA (Analysis of Variance). Additionally, stress-strain diagrams of the composite samples were compared with those of the base metal and processed samples without powder. The results showed that adding aluminum oxide powder increases tensile strength. Moreover, a rotational speed of 1600 rpm, a feed rate of 40 mm/min, and a powder amount of 0.6 grams resulted in the highest tensile strength. In the regression model for tensile strength, the linear term of the equation had a more significant impact than the quadratic and interaction terms.

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