Experimental study to optimize cold working, aging temperature, and time on the properties of AA6061 tubes: analysis using design of experiment

Abstract

The purpose of this study is to examine the impact of various process parameters, such as cold work, aging temperature, and aging time, on the yield strength, ultimate tensile strength (UTS), and elongation of AA6061 tubes. The experimental plan is carried out, and the data is analyzed using Design Expert software. Main effects plots and interaction plots are generated to visually examine the effects of individual factors and the interaction between two factors on the output response variables. ANOVA analysis is conducted to assess the statistical significance of the model and individual model coefficients. The results reveal that all input factors had a significant impact on yield, whereas cold work and temperature and their interaction are significant for UTS. However, the model is not significant for elongation. The most notable finding is that the aging temperature’s effect is significant than the other two factors. These study findings can inform future experiments or process optimization efforts by considering the combined impact of these factors and their interactions. The study also found that the optimal temperature range is between 155°C to 170°C, along with a recommended cold work percentage of 10% or more and preferred time of above 10 h up to overage time. The model achieved an overall accuracy rate of over 90%, indicating its ability to predict the response variable with a high degree of precision.