Thesis (M.Sc.) - Cairo University - Faculty of Engineering - Department of Mechanical Design and Production

Friction Stir Welding (FSW) is a solid-state welding technique that employs frictional heat to join a wide variety of materials in different applications. Despite the low heat input, friction stir welds are prone to significant residual stresses and deformations owing to the uneven heating and cooling cycles associated with the process by nature. The current investigation explored how the residual states of AA6063 friction stir welds responded to the variations in four input parameters plus their interactions. The significance of the input parameters and interactions was evaluated via the design of experiments. All experimental design trials were conducted with the aid of finite element simulation. For prediction purposes, linear regression models were developed in terms of significant variables only

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