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

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)

Experimentation flowchart of the UWFSW

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

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 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 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

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

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

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

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

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

n	UTS			WNH

	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

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

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

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

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

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

DOI: https://doi.org/10.2478/msp-2022-0013 | Journal eISSN: 2083-134X | 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: Sciendo

In partnership with: Paradigm Publishing Services

Publication frequency: 4 times per year

Keywords:

desirability approach

Related subjects:

Materials sciences,

Materials sciences, other,

Functional and smart materials,

Materials characterization and properties

© 2022 Ibrahim Sabry, A.M. Hewidy, published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

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