In-situ nanocomposite in friction stir welding of 6061-T6 aluminum alloy to AZ31 magnesium alloy

Prior to friction stir welding (FSW), silicon carbide (SiC) nanopowders were placed inside the groove on the adjacent side of magnesium sheet. In order to make a good distribution of these nanoparticles, first, friction stir processing (FSP) with a pinless tool was conducted on this side. Second, using a frustum pin tool, a combination of two travel speeds (25 and 35 mm/min) and three rotation speeds (550, 600 and 650 rpm) were employed to obtain the optimal conditions for FSW of AZ31 magnesium alloy to 6061 aluminum alloy. The joint fabricated at 35 mm/min and 650 rpm, exhibited improvement of 28% in tensile strength and enhancement about three times in elongation, compared with the joint without nanoparticles. SiC nanoparticles had an effective role on the grain refining of the stirred zone and improving the microstructural characteristics of the banded structure zone. Due to the decreased grain size and the presence of ceramic nanoparticles (SiC) with high value of hardness, the hardness level of the reinforced samples was greater than that of the non-reinforced samples. Fracture of the non-reinforced sample was completely brittle, while in the reinforced samples, fracture features changed to the ductile mode.