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Abstract
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In this study, response surface methodology in conjunction with a central composite design was
applied to predict the grain size and hardness of friction stir-welded AA 7020 aluminum alloy
joints. For this purpose, three welding parameters, including tool rotational speed, traverse
speed, and tool axial force, at five levels and 20 runs were considered. In order to validate the
predicted models, the analysis of variance was performed. Hardness and microstructural features
of the joints were investigated using microhardness test and optical microscopy, respectively.
In addition, the influences of friction stir welding parameters on grain size and hardness
of the joints were examined thoroughly. The analysis of variance results revealed that the
developed models were significant and accurate to predict the responses. Furthermore, with
increasing the heat input, the hardness of the joints decreased, where the grain size increased
continuously. In addition, the optimized condition for achieving the lowest grain size and
highest hardness of the joints was reached as 800 rpm, 125 mm/min and 8 kN.
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