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<p>This study investigates aluminum metal matrix composites (AMCs) reinforced with silicon carbide (SiC) particles (0–5&#xa0;wt.% - 40–50&#xa0;µm average size), focusing on process optimization and weldability characteristics. Using the Taguchi L27 orthogonal array, three critical stir casting parameters were optimized: SiC content (0–5&#xa0;wt.%), melting temperature (680–720&#xa0;°C), and stirring duration (10–20&#xa0;min). Analysis of variance (ANOVA) identified SiC content as most influential factor (74.59% contribution), followed by melting temperature (16.28%) and stirring duration (1.13%). The optimal parameters were determined to be 5&#xa0;wt.% SiC, 720&#xa0;°C melting temperature, and 20&#xa0;min stirring time, achieving maximum hardness of 65 BHN. Weldability studies using the Houldcroft test evaluated hot cracking susceptibility during Tungsten Inert Gas (TIG) welding with ER4043 filler material. Microstructural analysis revealed distinct features: spheroidal MgZn<sub>2</sub> and FeAl<sub>3</sub> intermetallic particles naturally present in the AA7075, dispersed Mg<sub>2</sub>Si precipitates in the partially melted zone, and cellular dendritic structures in the fusion zone. The nondestructive evaluation confirmed the absence of hot cracking, demonstrating the effectiveness of ER4043 filler material in crack mitigation.</p>

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Optimization of Processing Parameters in TIG-Welded Al-Mg-SiC Metal Matrix Composites Using Taguchi Method

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • N. Senthilkannan,
  • S. Omprakasam,
  • R. Raghu,
  • M. Thenarasu

摘要

This study investigates aluminum metal matrix composites (AMCs) reinforced with silicon carbide (SiC) particles (0–5 wt.% - 40–50 µm average size), focusing on process optimization and weldability characteristics. Using the Taguchi L27 orthogonal array, three critical stir casting parameters were optimized: SiC content (0–5 wt.%), melting temperature (680–720 °C), and stirring duration (10–20 min). Analysis of variance (ANOVA) identified SiC content as most influential factor (74.59% contribution), followed by melting temperature (16.28%) and stirring duration (1.13%). The optimal parameters were determined to be 5 wt.% SiC, 720 °C melting temperature, and 20 min stirring time, achieving maximum hardness of 65 BHN. Weldability studies using the Houldcroft test evaluated hot cracking susceptibility during Tungsten Inert Gas (TIG) welding with ER4043 filler material. Microstructural analysis revealed distinct features: spheroidal MgZn2 and FeAl3 intermetallic particles naturally present in the AA7075, dispersed Mg2Si precipitates in the partially melted zone, and cellular dendritic structures in the fusion zone. The nondestructive evaluation confirmed the absence of hot cracking, demonstrating the effectiveness of ER4043 filler material in crack mitigation.