Experimental investigation and optimization of friction stir welding parameters to manufacture AA6061-B4C composite material using design of experiments

IF 2 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

International Journal of Mechanical and Materials Engineering Pub Date : 2025-09-30 DOI:10.1186/s40712-025-00328-2

C. Manjunatha, Sreenivasa T. N, Madhusudhana S. V, Lakshmikant Shivanayak, B. J. Panditharadhya, C. Durga Prasad, Habib Masum, C. Hemanth Kumar, Adem Abdirkadir Aden

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Abstract

This study presents an experimental investigation into the friction stir welding (FSW) of AA6061 aluminum alloy reinforced with 10 wt% boron carbide (B₄C) particles, aiming to optimize process parameters for enhanced mechanical performance. A square tool profile was introduced and compared with cylindrical tapered and cylindrical full-threaded profiles to assess its influence on weld quality. Using the Taguchi method with an L27 orthogonal array, the effects of tool rotational speed (700, 1000, 1400 rpm), welding speed (40, 50, 63 mm/min), and tool profile were systematically examined with respect to the ultimate tensile strength (UTS) of the welded joints. The results revealed that tool rotational speed (N) had the most significant influence on UTS, followed by welding speed (S) and tool profile (P). The optimal combination of 700 rpm rotational speed, 40 mm/min welding speed, and square tool profile (N1S1P2) achieved a Maximum ultimate tensile UTS of 126.88 MPa. Statistical validation using analysis of variance (ANOVA) and signal-to-noise (S/N) ratio analysis confirmed the significance of the selected parameters. Furthermore, microstructural and fractographic analyses demonstrated a uniform dispersion of B₄C particles and enhanced load-bearing characteristics. This study highlights the effectiveness of using B₄C reinforcement and square tool geometry in improving FSW joint strength, offering valuable insights for advanced composite welding applications.

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采用试验设计方法对制备AA6061-B4C复合材料的搅拌摩擦焊工艺参数进行了试验研究和优化

采用10 wt%碳化硼（B4C）颗粒增强AA6061铝合金，进行搅拌摩擦焊接（FSW）试验研究，优化工艺参数，提高力学性能。介绍了一种方形刀具轮廓，并将其与圆柱锥形和圆柱全螺纹轮廓进行了比较，以评估其对焊接质量的影响。采用L27正交阵列的田口法，系统考察了刀具转速（700、1000、1400 rpm）、焊接速度（40、50、63 mm/min）和刀具轮廓对焊接接头极限抗拉强度的影响。结果表明，刀具转速(N)对UTS的影响最为显著，其次是焊接速度(S)和刀具轮廓(P)。700 rpm转速、40 mm/min焊接速度和方形刀具轮廓（N1S1P2）的最佳组合实现了126.88 MPa的最大极限拉伸UTS。采用方差分析（ANOVA）和信噪比分析（S/N）进行统计验证，证实了所选参数的显著性。此外，显微组织和断口分析表明，B4C颗粒均匀分散，承载特性增强。该研究强调了使用B4C增强和方形工具几何形状在提高FSW连接强度方面的有效性，为先进的复合材料焊接应用提供了有价值的见解。

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