Underwater friction-stir welding of a stir-cast AA6061-SiC metal matrix composite: optimization of the process parameters, microstructural characterization, and mechanical properties

Ibrahim Sabry; A.M. Hewidy

doi:10.2478/msp-2022-0013

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Underwater friction-stir welding of a stir-cast AA6061-SiC metal matrix composite: optimization of the process parameters, microstructural characterization, and mechanical properties

Materials Science-Poland

Volume 40 (2022): Issue 1 (March 2022)

By: Ibrahim Sabry and A.M. Hewidy

Open Access

|Jul 2022

Figures & Tables

Table 1

The chemical make-up of 6061 Al-alloy

Element	Mg	Si	Fe	Cu	Mn	Zn	Cr	Ti	Al
Wt.%	1.1	0.55	0.4	0.10	0.9	0.25	0.04	0.12	Remainder

Schematic representation of UWFSW **(A)** UWFSW welding fixture. **(B)** Photo of a tool **(C)** tool dimension **(D)** specimens of 6061/18% SiC AMC

**(A)** Photos of the specimens after tensile test. **(B)** Photos of the specimens before tensile test. **(C)** Dimensions of tensile test specimens (dimensions are in millimeter)

Table 2

UWFSW process parameters and their limits

	Level
Parameter	−1	0	1
Silicon carbide (SiC) (%)	5	10	18
Rotation speed (N) (rpm)	1,000	1,400	1,800
Travel speed (S) (mm/min)	10	20	30

Table 3

Full factorial design matrix

Run	SiC	N	S	UTS (MPa) code	VHNode
1	5	1,000	10	205.00	64.544
2	10	1,000	10	196.00	55.243
3	18	1,000	10	190.00	52.942
4	5	1,000	20	200.00	55.980
5	10	1,000	20	190.00	53.679
6	18	1,000	20	180.00	51.378
7	5	1,000	30	190.00	55.198
8	10	1,000	30	185.00	52.897
9	18	1,000	30	174.00	50.596
10	5	1,400	10	202.00	56.113
11	10	1,400	10	186.40	53.812
12	18	1,400	10	174.70	51.511
13	5	1,400	20	195.30	54.548
14	10	1,400	20	183.70	52.247
15	18	1,400	20	172.30	49.946
16	5	1,400	30	193.10	53.766
17	10	1,400	30	180.03	51.465
18	18	1,400	30	170.32	49.164
19	5	1,800	10	196.00	56.113
20	10	1,800	10	185.10	52.380
21	18	1,800	10	176.20	50.079
22	5	1,800	20	191.30	53.117
23	10	1,800	20	184.20	50.816
24	18	1,800	20	171.20	48.515
25	5	1,800	30	187.10	52.335
26	10	1,800	30	181.10	50.034
27	18	1,800	30	166.30	47.732

Stress–strain curve of unwelded AA 6061 Al-SiC alloy specimens from the tensile test

Stress-strain curve of welded AA 6061 Aluminium-silicon carbide alloy specimens from the tensile test for weld speed 10 mm/min

Table 4

ANOVA results for UTS

Exporter	Squares of sum	df	Square of mean	F-value	p-value
Model	2,637.03	9	293.00	52.07	<0.0001	Significant
A-SiC	1,896.87	1	1,896.87	337.08	<0.0001
B-N	73.62	1	273.62	48.62	<0.0001
C-S	397.11	1	397.11	70.57	<0.0001
AB	6.56	1	6.56	1.17	0.2952
AC	1.37	1	1.37	0.24	0.6285
BC	30.72	1	30.72	5.46	0.0320
A²	47.11	1	47.11	8.37	0.0101
B²	19.92	1	19.92	3.54	0.0771
C²	0.10	1	0.10	0.018	0.8943
Residual	95.66	17	5.63
Cor Total	2,732.69	26

Table 5

ANOVA results for microhardness

Exporter	Squares of sum	df	Square of mean	F-value	p-value
Model	260.47	9	28.94	21.80	<0.0001	Significant
A-SiC	138.06	1	138.06	104.02	<0.0001
B-N	56.45	1	56.45	42.53	<0.0001
C-S	51.50	1	51.50	38.80	<0.0001
AB	2.94	1	2.94	2.22	0.1548
AC	6.75	1	6.75	5.09	0.0376
BC	2.58	1	2.58	1.95	0.1810
A²	0.17	1	0.17	0.13	0.7234
B²	1.32	1	1.32	0.99	0.3331
C²	4.43	1	4.43	3.34	0.0852
Residual	22.56	17	1.33
	283.03	26

Table 6

The optimization criteria that were applied in this study

Parameters/responses of the process	Goal	The bare minimum	The bare maximum	Significance
A:SiC	Is in range	6.03417	16.9658	3
B:N	Is in range	10,063	1,736.36	3
C:S	Is in range	10	28.409	3
UTS	Maximize	186.3	202.9	3
WNH	Maximize	47.732	64.544	3

The influence of UWFSW parameters on the UTS of the UWFSW joint is shown by a perturbation plot

The influence of N and S on the UTS of the UWFSW joint is represented by contour plots: **(A)** plot of contour 2D; **(B)** plot of contour 3D

The influence of SiC and S on the UTS of the UWFSW joint is represented by contour plots: **(A)** plot of contour 2D; **(B)** plot of contour 3D

The influence of UWFSW parameters on the WNH is represented by a perturbation plot

The influence of N and S on the WNH of the UWFSW joint is represented by contour plots: **(A)** plot of contour 2D; **(B)** plot of contour 3D

The influence of SiC and S on the WNH of the UWFSW joint is represented by contour plots: **(A)** plot of contour 2D; **(B)** plot of contour 3D

A graphic that predicts the best UWFSW process parameters

UWFwelded macrostructure for 6061/18% **(A)** UWFSW at 1,000 rpm **(B)** UWFSW at 1,800 rpm SiC composite

Table 7

The outcomes of the experiments as well as the values anticipated by the Design-Expert software for all numbers of runs

n	UTS			WNH
n	Actual UTS	Predicted UTS	Error%	Actual WNH	Predicted WNH	Error%
1	205.000	204.909	0.091	64.544	59.172	5.372
2	196.000	192.538	3.462	55.243	55.779	−0.536
3	190.000	184.806	5.194	52.942	53.658	−0.716
4	200.000	200.218	−0.218	55.980	57.530	−1.550
5	190.000	187.846	2.154	53.679	54.137	−0.458
6	180.000	180.114	−0.114	51.378	52.017	−0.639
7	190.000	195.526	−5.526	55.198	55.888	−0.690
8	185.000	183.154	1.846	52.897	52.496	0.401
9	174.000	175.422	−1.422	50.596	50.375	0.221
10	202.000	200.937	1.063	56.113	57.431	−1.318
11	186.400	188.566	−2.166	53.812	54.038	−0.226
12	174.700	180.833	−6.133	51.511	51.917	−0.406
13	195.300	196.245	−0.945	54.548	55.789	−1.241
14	183.700	183.874	−0.174	52.247	52.396	−0.149
15	172.300	176.142	−3.842	49.946	50.276	−0.330
16	193.100	191.554	1.546	53.766	54.147	−0.381
17	180.030	179.182	0.848	51.465	50.755	0.710
18	170.320	171.450	−1.130	49.164	48.634	0.530
19	196.000	196.965	−0.965	56.113	55.690	0.423
20	185.100	184.593	0.507	52.380	52.297	0.083
21	176.200	176.861	−0.661	50.079	50.177	−0.098
22	191.300	192.273	−0.973	53.117	54.048	−0.931
23	184.200	179.902	4.298	50.816	50.655	0.161
24	171.200	172.169	−0.969	48.515	48.535	−0.020
25	187.100	187.582	−0.482	52.335	52.406	−0.071
26	181.100	175.210	5.890	50.034	49.014	1.020
27	166.300	167.478	−1.178	47.732	46.893	0.839

UWFSW optical microscopic for composite material at 1,000 rpm and 6,061/5%, SiC. **(A)** At 1,000 rpm and 6,061/10%, SiC. **(B)** At 1,000 rpm and 6,061/18%, SiC. **(C)** At 1,800 rpm and 6,061/5%, SiC min. **(D)** At 1,800 rpm and 6,061/10%, SiC. **(E)** At 1,800 rpm, SiC **(F)** and 6,061/18% SiC **(G)** Microstructure of UWFSW for AL6061 at speed 1,000 rpm **(H)** Microstructure of UWFSW for AL6061 at speed 1,400 rpm **(I)** UWFSW for AL6061 at speed 1,800 rpm

XRD patterns of AA6061/SiC with different content of SiC particles

References

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Articles in this issue

DOI: https://doi.org/10.2478/msp-2022-0013 | Journal eISSN: 2083-134X (formerly 2083-124X) | Journal ISSN: 2083-1331

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Language: English

Page range: 101 - 115

Submitted on: Feb 23, 2022

Accepted on: May 9, 2022

Published on: Jul 4, 2022

Published by: Wroclaw University of Science and Technology

In partnership with: Paradigm Publishing Services

Keywords:

UWFSW,

UTS,

MHV,

RSM,

optimization,

desirability approach

Related subjects:

Materials sciences,

Materials sciences, other,

Nanomaterials,

Functional and smart materials,

Materials characterization and properties

© 2022 Ibrahim Sabry, A.M. Hewidy, published by Wroclaw University of Science and Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

Volume 40 (2022): Issue 1 (March 2022)

Underwater friction-stir welding of a stir-cast AA6061-SiC metal matrix composite: optimization of the process parameters, microstructural characterization, and mechanical properties

Figures & Tables

Table 1

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Table 2

Table 3

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Table 4

Table 5

Table 6

Fig. 6

Fig. 7

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Fig. 9

Fig. 10

Fig. 11

Fig. 12

Fig. 13

Fig. 14

Fig. 15

Table 7

Fig. 16

Fig. 17

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