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<p>This study examined the incorporation of Al<sub>2</sub>O<sub>3</sub> ceramic particles in the stir zone (SZ) of 12 mm thick AA6082-T6 friction stir welded (FSWed) joints. The effects of different ceramic particle concentrations of 0, 4, 8, and 12 vol.% on microstructure, hardness, tensile properties, and fracture behavior of the FSWed joints were evaluated. Microstructural analysis revealed significant grain refinement in the SZ of the unreinforced joint (AA6082/0), with a 67% reduction in grain size from 23.32 ±5.21 μm in the initial AA6082-T6 plate to 7.64 ±3.52 μm. The addition of Al<sub>2</sub>O<sub>3</sub> particles moderated this refinement, yielding grain sizes of 16.71 ±3.51 μm, 18.21 ±2.21 μm, and 19.89 ±2.16 μm for 4, 8, and 12 vol.% Al<sub>2</sub>O<sub>3</sub>, respectively. Hardness in the composite stir zone (CSZ) improved by 9.1, 22.2, and 30.3% for the 4, 8, and 12 vol.% Al<sub>2</sub>O<sub>3</sub> joints compared to the AA6082/0 joint, with high hardness reaching 129 ± 4 HV. The ultimate tensile strength peaked at 302.2 ±5.3 MPa for the joint with 8 vol.% Al<sub>2</sub>O<sub>3</sub>, representing an increase from 270.6 ±6.1 MPa for the unreinforced joint, before declining sharply to 204.5 ±8.1 MPa at 12 vol.% Al<sub>2</sub>O<sub>3</sub>. Correspondingly, the elongation decreased from 14.5 ± 0.7% to 5.7 ± 0.8% at higher Al<sub>2</sub>O<sub>3</sub> concentrations of 12 vol.%, highlighting the transition from ductile to brittle fracture behavior. Fracture surface analysis corroborated this observation, revealing a shift from dimple-dominated ductile fracture to a mixed mode with tearing ridges and particle-rich regions as the Al<sub>2</sub>O<sub>3</sub> concentration increased.</p>

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Microstructural Evolution and Mechanical Performance Analysis of Friction Stir Welded AA6082-T6 Enhanced with Al2O3 Interlayer Particles

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Waheed S. Barakat,
  • Mohamed M. Z. Ahmed,
  • Ali Abd El-Aty,
  • Mohamed I. A. Habba

摘要

This study examined the incorporation of Al2O3 ceramic particles in the stir zone (SZ) of 12 mm thick AA6082-T6 friction stir welded (FSWed) joints. The effects of different ceramic particle concentrations of 0, 4, 8, and 12 vol.% on microstructure, hardness, tensile properties, and fracture behavior of the FSWed joints were evaluated. Microstructural analysis revealed significant grain refinement in the SZ of the unreinforced joint (AA6082/0), with a 67% reduction in grain size from 23.32 ±5.21 μm in the initial AA6082-T6 plate to 7.64 ±3.52 μm. The addition of Al2O3 particles moderated this refinement, yielding grain sizes of 16.71 ±3.51 μm, 18.21 ±2.21 μm, and 19.89 ±2.16 μm for 4, 8, and 12 vol.% Al2O3, respectively. Hardness in the composite stir zone (CSZ) improved by 9.1, 22.2, and 30.3% for the 4, 8, and 12 vol.% Al2O3 joints compared to the AA6082/0 joint, with high hardness reaching 129 ± 4 HV. The ultimate tensile strength peaked at 302.2 ±5.3 MPa for the joint with 8 vol.% Al2O3, representing an increase from 270.6 ±6.1 MPa for the unreinforced joint, before declining sharply to 204.5 ±8.1 MPa at 12 vol.% Al2O3. Correspondingly, the elongation decreased from 14.5 ± 0.7% to 5.7 ± 0.8% at higher Al2O3 concentrations of 12 vol.%, highlighting the transition from ductile to brittle fracture behavior. Fracture surface analysis corroborated this observation, revealing a shift from dimple-dominated ductile fracture to a mixed mode with tearing ridges and particle-rich regions as the Al2O3 concentration increased.