Microstructural characteristics of AA6061-T6 composite joints formed by friction stir welding process and with different nanoparticulate
Keywords:
Friction Stir Welded (FSWed), Reinforcement Powders (RP), Composite Joints, Grain Structure.Abstract
The mechanical properties of a Friction Stir Welded (FSWed) joint of AA6061-T6 alloy were attempted to be improved by refining the microstructure and confining the coarsening of strengthening precipitates at Nugget Zone (NZ) and heat-affected zone (HAZ). Nanomaterial reinforced friction stir welding was a new field that promises to improve joint quality by forming composite joints. AA6061-T6 alloy composite joints containing two different nano reinforcement particles (RP): Silicon Carbide (SiC) and Boron Carbide (B4C) at different weight ratio 5 wt%, 10 wt%, and 15 wt% were fabricated via friction stir welding process (FSW). Reinforcement particles (RP) particles were smaller than 1μm in size, the Zener pinning action prevented grain growth, which occurs during the FSW process's recrystallization stage, and limited grain coarsening by limiting grain boundary path motion. Microstructure analysis of all FSWed composite joints revealed a remarkable degree of grain refinement at the HAZ and NZ. Mechanical testing showed that while B4C particles had more advantage in terms of hardness values when compare with reinforcement of SiC particles. Similarly reinforcement of SiC particles had more advantage in terms of tensile strength of the FSWed composite joints when compared with reinforcement of B4C particles. The hardness of composite joints increased in direct proportion to the increase in volume fraction. The trend in tensile strength in composite joints was the inverse of the trend in hardness. FSW process created voids and crack initiation at the RP/BM matrix interface in 15% volume fraction composite joints due to the non-homogeneous distribution of nano particles and poor interaction. As a result, during the stress test, these joints fractured prematurely. The SEM was used to examine particle distribution in weld zone and fractured surfaces of all the tension test samples. Composite joints with a volume fraction of 5% to 10% exhibited uniform particle distribution and mixed ductile and brittle fractures
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