Multiphysics computational modelling and experimental analysis of friction stir welding of aluminium alloy metal matrix composites (AAMMCs)

Abstract

Friction stir welding is a modern method for fabricating aluminium alloy metal matrix composites (AAMMCs) that significantly enhance the properties of the parent materials. In this study, Al2O3 particles were incorporated into a 6061-T6 aluminium matrix. Experimental and numerical modeling provided in-situ observations of particle-aluminium matrix mixing in the weld stir zone (SZ). Two different pin profiles, threaded and square, were used to fabricate the AAMMC joints. The threaded pin profile resulted in uniform dispersion and a homogeneous distribution of Al2O3 particles within the aluminium matrix. In contrast, the square pin profile led to defects in the SZ and a non-homogeneous particle distribution. The volume fraction mixing of the AA6061-T6 matrix and Al2O3 at the workpiece/tool interface from top to bottom was analyzed using a level set technique. Experimental results showed effective mixing of Al2O3 particles in the AA6061-T6 matrix with the threaded pin profile, resulting in a defect-free joint, uniform particle distribution, and ultra-fine grain refinement, with grain sizes reduced to 4.19 µm. The main shear texture components observed in the threaded pin joints included B/B̅ and C, along with deformed and recrystallized texture components such as Copper {112} 〈111〉, Brass {110} 〈112〉, Goss {011} 〈100〉, Cube {001} 〈101〉, and P {011} 〈112〉 . Additionally, joints fabricated using threaded pin profiles exhibited significantly higher tensile strength (up to 270 MPa) and microhardness (average of 120 HV0.2) compared to those with square-shaped pin profiles, which showed lower values of 240 MPa and 105 HV0.2, respectively. Thus, AAMMC joints made with threaded pins demonstrate ultra-fine grain refinement, increased high-angle grain boundaries, enhanced recrystallized texture components, and improved mechanical properties, resulting in superior overall joint performance.