Lightweight aluminum joint design: Enhancement of mechanical properties through novel inter-layer and powder additives in friction stir welding
Year: 2025
Type: article
Abstract: Friction Stir Welding (FSW) is a solid-state joining process that has gained prominence for its effectiveness in welding aluminum alloys, addressing common issues like porosity and thermal defects associated with traditional fusion welding. This study investigates the impact of inter-layers and powder additives on the mechanical properties and microstructure of Aluminum FSW joints. Specifically, the research explores two types of inter-layers: magnesium (Mg) ribbons and Lead-Tin alloy ribbons, and three reinforcement powders: Boron Carbide (B4C), Titanium Dioxide (TiO2), and Manganese (Mn). The effects of these modifications were assessed through mechanical testing and morphological characterization. Key output responses included shear strength, hardness, surface roughness, and wear resistance, with further analysis conducted via scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. Experiments were conducted, varying the types of inter-layers and reinforcement powders to systematically evaluate their impacts on weld quality. Results indicated that the highest shear strength is found when Manganese (Mn) powder additive is provided without inter-layer. Sn-Pb alloy inter-layer with Manganese powder additive gives the highest hardness and minimum wear rate. Magnesium (Mg) ribbon with Manganese (Mn) interlayer gives the lowest surface roughness. The scientific rationale behind these effects was thoroughly examined, providing a comprehensive analysis of the underlying mechanisms and evidence that support their significance.
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: diamond
Funder: United Arab Emirates University
OpenAlex ID: W4407134808