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<p>A comparative investigation has been conducted on friction stir welded (FSW) AA7020-T651 and AA5083-H111 aluminum alloys reinforced with B<sub>4</sub>C nanoparticles using four different joint configurations processed with tool rotational speed and traverse speed of 800&#xa0;rpm and 200&#xa0;mm/min, respectively. The resulting dissimilar joints were free of defects with a refined stir zone microstructure resulting from dynamic recrystallization during welding. The unreinforced dissimilar joint showed a yield strength of 165&#xa0;MPa and an ultimate tensile strength (UTS) of 315&#xa0;MPa; the addition of 3&#xa0;wt.% B4C showed significant improvement in the mechanical response with a yield strength of 212&#xa0;MPa (≈&#xa0;28.5%) and ultimate tensile strength of 355&#xa0;MPa (≈&#xa0;12.7%). The reinforced joint was also found to be superior than the base alloy in terms of joint efficiency (101.43%). Furthermore, stir zone hardness increased to ~ 117-122&#xa0;HV (≈&#xa0;55–60% higher than AA5083) due to grain refinement and particle strengthening. Hollomon analysis showed an increase in the coefficient of strength (<i>K</i>&#xa0;≈&#xa0;495&#xa0;MPa) and a decrease in the strain-hardening exponent (<i>n</i>&#xa0;≈&#xa0;0.107), which reflects an increase in strength with a decrease in ductility. Finite element simulations showed strong agreement with experimental results, with deviations within ~ 3-4%, confirming the reliability of the adopted model. This study establishes a direct correlation between B<sub>4</sub>C-induced microstructural modification, strain-hardening behavior, and joint efficiency in dissimilar AA7020/AA5083 FSW joints, providing a unified process–structure–property framework for reinforced dissimilar welds.</p>

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Synergistic Microstructural Evolution and Mechanical Response in B4C-Reinforced Dissimilar Friction Stir Welded AA7020-T651/AA5083-H111

  • 期刊论文

  • 发表日期：

    2026年4月20日

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  • Ambuj Saxena,
  • Adepu Kumaraswamy,
  • Ashish Kumar Srivastava,
  • Manish Maurya,
  • Manish Kumar Giri,
  • Ashish Kumar

摘要

A comparative investigation has been conducted on friction stir welded (FSW) AA7020-T651 and AA5083-H111 aluminum alloys reinforced with B4C nanoparticles using four different joint configurations processed with tool rotational speed and traverse speed of 800 rpm and 200 mm/min, respectively. The resulting dissimilar joints were free of defects with a refined stir zone microstructure resulting from dynamic recrystallization during welding. The unreinforced dissimilar joint showed a yield strength of 165 MPa and an ultimate tensile strength (UTS) of 315 MPa; the addition of 3 wt.% B4C showed significant improvement in the mechanical response with a yield strength of 212 MPa (≈ 28.5%) and ultimate tensile strength of 355 MPa (≈ 12.7%). The reinforced joint was also found to be superior than the base alloy in terms of joint efficiency (101.43%). Furthermore, stir zone hardness increased to ~ 117-122 HV (≈ 55–60% higher than AA5083) due to grain refinement and particle strengthening. Hollomon analysis showed an increase in the coefficient of strength (K ≈ 495 MPa) and a decrease in the strain-hardening exponent (n ≈ 0.107), which reflects an increase in strength with a decrease in ductility. Finite element simulations showed strong agreement with experimental results, with deviations within ~ 3-4%, confirming the reliability of the adopted model. This study establishes a direct correlation between B4C-induced microstructural modification, strain-hardening behavior, and joint efficiency in dissimilar AA7020/AA5083 FSW joints, providing a unified process–structure–property framework for reinforced dissimilar welds.