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<p>Friction stir welding (FSW) is a novel joining technique developed for high-strength aluminum alloys to address challenges associated with fusion welding. The AA6061 aluminum alloy has lately been utilized in friction stir welding for applications in aerospace, defense, and the marine industry, where it must withstand corrosive environments and non-uniform stresses. Although friction stir welds in AA6061 alloy have excellent mechanical properties, they lack sufficient corrosion resistance. The research shown that using a post-weld heat treatment of retrogression and reaging (RRA) on aluminum alloy welds markedly improved the corrosion resistance of the joints. The incorporation of Al₂O₃ nanoparticles using friction stir welding on a meticulously prepared butt-jointed base plate facilitated a modified chemical composition in the weld nugget. The microstructural analysis, hardness, and pitting corrosion of the nugget zone in FSW of AA6061 alloy were examined under various situations, including RRA condition, peak aged state (T6) condition, and the incorporation of Al₂O₃ nanoparticles. While RRA enhanced resistance to pitting corrosion, it did result in a minor reduction in hardness. The incorporation of alumina powder followed by the heating of RRA post-welding significantly enhanced its resistance to pitting corrosion.</p>

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Enhancement of corrosion resistance and mechanical properties in friction stir welded AA6061 alloy through post-weld heat treatment and Al₂O₃ nanoparticle addition

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Vijay R Khawale,
  • Pramod G. Musrif,
  • Rajasekaran Saminathan,
  • Satishkumar P,
  • Sanjay M Asutkar,
  • Sujitha K

摘要

Friction stir welding (FSW) is a novel joining technique developed for high-strength aluminum alloys to address challenges associated with fusion welding. The AA6061 aluminum alloy has lately been utilized in friction stir welding for applications in aerospace, defense, and the marine industry, where it must withstand corrosive environments and non-uniform stresses. Although friction stir welds in AA6061 alloy have excellent mechanical properties, they lack sufficient corrosion resistance. The research shown that using a post-weld heat treatment of retrogression and reaging (RRA) on aluminum alloy welds markedly improved the corrosion resistance of the joints. The incorporation of Al₂O₃ nanoparticles using friction stir welding on a meticulously prepared butt-jointed base plate facilitated a modified chemical composition in the weld nugget. The microstructural analysis, hardness, and pitting corrosion of the nugget zone in FSW of AA6061 alloy were examined under various situations, including RRA condition, peak aged state (T6) condition, and the incorporation of Al₂O₃ nanoparticles. While RRA enhanced resistance to pitting corrosion, it did result in a minor reduction in hardness. The incorporation of alumina powder followed by the heating of RRA post-welding significantly enhanced its resistance to pitting corrosion.