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<p>The objective of this study is to investigate the effects of friction stir welding (FSW) with alumina nanoparticles on the metallurgical behavior, hardness, and wear resistance of dissimilar aluminum alloys 6061 and 5083, at a rotational speed of 1100&#xa0;rpm and a traverse speed of 32&#xa0;mm/min. In this regard, microstructural characterization was performed using metallography, micro-hardness testing, and wear analysis. The results revealed that increasing the number of welding passes from one to two significantly refined the grain size in the stir zone compared to the base metals and led to a more uniform distribution of nanoparticles. Despite the considerable grain refinement, the presence of intermetallic compounds and subsequent coarsening of Mg₂Si and Al₂CuMg phases due to welding-induced heat input caused a reduction in hardness and wear resistance. However, the addition of alumina nanoparticles effectively hindered grain coarsening through a pinning mechanism, resulting in improved hardness and wear resistance. Moreover, increasing the nanoparticle content from 1 Wt. % to 2 Wt. % enhanced both hardness and wear resistance while reducing the coefficient of friction. The wear test results indicated that double-pass welded samples containing nanoparticles exhibited superior performance, with a wear loss of 42.5&#xa0;mg and a coefficient of friction of 0.38 under abrasive wear mechanisms, compared to single-pass samples without nanoparticles, which showed a wear loss of 116.3&#xa0;mg and a coefficient of friction of 0.9 with an adhesive wear mechanism.</p>

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Effects of Friction Stir Welding of 6061-T6 To 5083-H11 Aluminum Alloys Reinforced with Al2O3 on Microstructure, Hardness, and Wear Resistance

  • 期刊论文

  • 发表日期：

    2025年9月25日

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  • Mohammad Karimi Ivanaki,
  • Davood Afshari,
  • Esmaeil Poursaeidi

摘要

The objective of this study is to investigate the effects of friction stir welding (FSW) with alumina nanoparticles on the metallurgical behavior, hardness, and wear resistance of dissimilar aluminum alloys 6061 and 5083, at a rotational speed of 1100 rpm and a traverse speed of 32 mm/min. In this regard, microstructural characterization was performed using metallography, micro-hardness testing, and wear analysis. The results revealed that increasing the number of welding passes from one to two significantly refined the grain size in the stir zone compared to the base metals and led to a more uniform distribution of nanoparticles. Despite the considerable grain refinement, the presence of intermetallic compounds and subsequent coarsening of Mg₂Si and Al₂CuMg phases due to welding-induced heat input caused a reduction in hardness and wear resistance. However, the addition of alumina nanoparticles effectively hindered grain coarsening through a pinning mechanism, resulting in improved hardness and wear resistance. Moreover, increasing the nanoparticle content from 1 Wt. % to 2 Wt. % enhanced both hardness and wear resistance while reducing the coefficient of friction. The wear test results indicated that double-pass welded samples containing nanoparticles exhibited superior performance, with a wear loss of 42.5 mg and a coefficient of friction of 0.38 under abrasive wear mechanisms, compared to single-pass samples without nanoparticles, which showed a wear loss of 116.3 mg and a coefficient of friction of 0.9 with an adhesive wear mechanism.