Effect of tool rotational speed on the particle distribution in friction stir welding of AA6092/17.5 SiCp-T6 composite plates and its consequences on the mechanical property of the joint

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This study investigates the effect of tool rotational speed (TRS) on particle distribution in nugget zone (NZ) through quantitative approach and its consequences on the mechanical property of friction stir welded joints of AA6092/17.5 SiCp-T6 composite. 6 mm thick plates are welded at a constant tool tilt angle of 2° and tool traverse speed of 1 mm/s by varying the TRS at 1000 rpm, 1500 rpm and 2000 rpm with a taper pin profiled tool. Microstructure analysis shows large quantity of uniformly shaped smaller size SiC particle with lower average particle area which are homogeneously distributed in the NZ. The fragmentation of bigger size particles has been observed because of abrading action of the hard tool and resulting shearing effect and severe stress generation due to the rotation of tool. The particles occupy maximum area in the matrix compared to that of the base material (BM) due to the redistribution of broken particles as an effect of TRS. The migration of particles towards the TMAZ-NZ transition zone has been also encountered at higher TRS (2000 rpm). The microhardness analysis depicts variation in average hardness from top to bottom of the NZ, minimum for 1500 rpm and maximum for 2000 rpm. The impact strength at 1000 rpm and 1500 rpm remains close to that of BM (21.6 J) while 2000 rpm shows the accountable reduction. The maximum joint efficiency has been achieved at 1500 rpm (84%) and minimum at 1000 rpm (68%) under tensile loading. Fractographic analysis shows mixed mode of failure for BM, 1000 rpm and 1500 rpm, whereas 2000 rpm shows the brittle mode of failure.