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<p>Fusion welding of Al alloys often demonstrates poor mechanical performance due to high thermal conductivity, porosity formation, and development of coarse grain structures in the fusion zone. Conventional ER-4043 filler metals provide only marginal improvement in strength and hardness because they lack adequate grain refinement and reinforcement capability. To overcome these challenges, the current research aims to manufacture silicon carbide (SiC) based nanoparticle-reinforced casted filler to evaluate its performance on the mechanical and microstructural properties of gas tungsten arc welded (GTAW) Al-2024 joints. The effect of the SiC nanoparticles has been assessed at process variables such as welding current and gas flow rate on the ultimate tensile strength (UTS) and microhardness (MH). The results revealed that adding 5% SiC resulted in a rise in the UTS from 310 to 410&#xa0;MPa (an improvement of 24.39%) and the MH from 93 to 129 HV (an improvement of 27.91%) of GTAW Al-2024 joints. The optical microscopy microstructure analysis depicted that grain size reduces, and grain structure changed from the coarse to fine dendritic with the addition of 5% SiC nanoparticles. A scanning electron microscope (SEM) showed that adding 5% SiC caused a uniform distribution of fine eutectic phases at the grain boundaries and formed a coarse and fine dimple structure which significantly improved the performance of weld joints. Conversely, large voids and shallow dimples have been observed at the addition of 10% SiC nanoparticles in the casted filler due to the irregular SiC nanoparticle distribution that restricts the diffusion rate at the welded region. These findings establish a novel and scalable approach for producing high-strength aluminum welds, with great potential for advanced automotive and aerospace manufacturing.</p>

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Evaluation of SiC Nanoparticles-based Reinforced Casted Filler Effects on the Mechanical Performance of Al-2024 GTAW Welded Joints

  • 期刊论文

  • 发表日期：

    2026年1月26日

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  • Muhammad Jawad,
  • Muhammad Waqas Hanif,
  • Kashif Ishfaq,
  • Mirza Jahanzaib,
  • Zaheer Ahmad,
  • Hassan Habib

摘要

Fusion welding of Al alloys often demonstrates poor mechanical performance due to high thermal conductivity, porosity formation, and development of coarse grain structures in the fusion zone. Conventional ER-4043 filler metals provide only marginal improvement in strength and hardness because they lack adequate grain refinement and reinforcement capability. To overcome these challenges, the current research aims to manufacture silicon carbide (SiC) based nanoparticle-reinforced casted filler to evaluate its performance on the mechanical and microstructural properties of gas tungsten arc welded (GTAW) Al-2024 joints. The effect of the SiC nanoparticles has been assessed at process variables such as welding current and gas flow rate on the ultimate tensile strength (UTS) and microhardness (MH). The results revealed that adding 5% SiC resulted in a rise in the UTS from 310 to 410 MPa (an improvement of 24.39%) and the MH from 93 to 129 HV (an improvement of 27.91%) of GTAW Al-2024 joints. The optical microscopy microstructure analysis depicted that grain size reduces, and grain structure changed from the coarse to fine dendritic with the addition of 5% SiC nanoparticles. A scanning electron microscope (SEM) showed that adding 5% SiC caused a uniform distribution of fine eutectic phases at the grain boundaries and formed a coarse and fine dimple structure which significantly improved the performance of weld joints. Conversely, large voids and shallow dimples have been observed at the addition of 10% SiC nanoparticles in the casted filler due to the irregular SiC nanoparticle distribution that restricts the diffusion rate at the welded region. These findings establish a novel and scalable approach for producing high-strength aluminum welds, with great potential for advanced automotive and aerospace manufacturing.