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<p>In the present work, the surface of Al 6061 alloy is modified with titanium carbide (TiC) coating material by tungsten inert gas (TIG) cladding to enhance its functional performance. The influence of TIG welding current (50, 70, and 90&#xa0;A) on microstructure, coating formation, and mechanical performance was systematically investigated. Cross-sectional SEM analysis confirmed sound metallurgical bonding between the coating and the Al 6061 alloy, while energy-dispersive x-ray spectroscopy and XRD investigations confirmed the presence of Al-TiC composite phases. The developed coating exhibited fracture toughness between 6.12 and 7.16&#xa0;MPa.m<sup>1/2</sup>, and three to four times improved hardness (440-492 HV<sub>0.05</sub>) as compared to uncoated Al alloy. Dry sliding wear tests revealed a considerable improvement in wear resistance; the coated samples showed a twofold to threefold reduction in material loss as compared to the uncoated alloy, primarily attributed to the TiC-reinforced layer. The analysis also revealed that TIG processing current has a significant impact on the microstructure as well as the mechanical performance of the produced coating.</p>

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Microstructural and Mechanistic Insights into Al-TiC Metal Matrix Composite Coating Formation on Aluminum 6061 by Tungsten Inert Gas Cladding Process

  • 期刊论文

  • 发表日期：

    2026年1月26日

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  • D. Tijo,
  • Amal Shafi Abdulla,
  • Aswin S. Nair,
  • Geo Amal Mathew,
  • S. Harisankar

摘要

In the present work, the surface of Al 6061 alloy is modified with titanium carbide (TiC) coating material by tungsten inert gas (TIG) cladding to enhance its functional performance. The influence of TIG welding current (50, 70, and 90 A) on microstructure, coating formation, and mechanical performance was systematically investigated. Cross-sectional SEM analysis confirmed sound metallurgical bonding between the coating and the Al 6061 alloy, while energy-dispersive x-ray spectroscopy and XRD investigations confirmed the presence of Al-TiC composite phases. The developed coating exhibited fracture toughness between 6.12 and 7.16 MPa.m1/2, and three to four times improved hardness (440-492 HV0.05) as compared to uncoated Al alloy. Dry sliding wear tests revealed a considerable improvement in wear resistance; the coated samples showed a twofold to threefold reduction in material loss as compared to the uncoated alloy, primarily attributed to the TiC-reinforced layer. The analysis also revealed that TIG processing current has a significant impact on the microstructure as well as the mechanical performance of the produced coating.