Selection of groove dimension in the fabrication of particulate reinforced aluminium matrix composites using friction stir welding

Abstract

Selecting groove dimensions has always been challenging for fabricating particulate reinforced aluminium matrix composites using friction stir welding. To address this, heat transfer physics coupled with the level set method was used to estimate material mixing between 6061-T6 Al-matrix and Al2O3 using the COMSOL Multiphysics tool. Groove dimensions of 2 mm width and depth resulted in the absence of volumetric/tunnel defects, nearly symmetric distribution, and minimal agglomeration of Al2O3 powder particles. This combination achieved an optimum trade-off between strength and ductility.