Study of Friction Stir Welding Parameters Affecting the Microstructure and Mechanical Properties of Silicon Carbide Reinforced Aluminum 6061

The objective of this study is to investigate the effects of parameters on the metallurgical and mechanical properties of friction stir welding of aluminum AA6061 reinforced with Silicon Carbide micro-particles of 5 microns. A study on the effect of silicon particle addition in friction stir welding using a pinless tool in the first pass showed better silicon carbide dispersion in the welding zone compared to using a square pin tool. A study on the effect of transverse speed 26, 34, and 50 mm/min and rotational speed 920,1,040, and 1,350 rpm on the top welds appearance showed complete welds at all transverse speed which exhibited cracks along the weld line and the lowest hardness value of 54.21 HV. As for the microstructure, uniform silicon carbide particle distribution was observed at a travel speed of 26 mm/min and a welding rotation speed of 1350 rpm. This resulted silicon carbide partical dispersed in a homogeneous with aluminum matrix and obtain the highest hardness of 77.16 HV. Keywords: Friction Stir Welding, Aluminium, Aluminium Composite, Silicon Carbide Particle