Influence of Friction Stir Welding Process Parameters on Mechanical Properties of AA6061-9 wt.% SiC Composites

Aluminum-based composites reinforced with ceramics particles are the most preferred materials for applications in the aerospace sector due to their superior properties. Friction stir welding is a novel potential joining process owing to its low distortion and environmentally friendly characteristics, and friction stir welding is widely used for joining aluminum matrix composites without any defects which as boosted the applications of composites. The present research work reports the results of experimental studies carried out on the effect of friction stir welding parameters on UTS and Vickers hardness of AA6061-9 wt.% SiC composite. The friction stir welding was carried out with tool rotation speed of 600–900 rpm in a step of 150, with the axial load 4–6 kN in a step of 1; the transverse speed adopted was 45 mm/min, with different tool pin profiles such as cylindrical, square, and taper. Results reveal that the welded joints produced at 750 rpm tool rotational speed, with the axial load of 5 kN using a square pin tool profile exhibits higher UTS of 124.3 MPa and Vickers hardness of 98.11; further, SEM microphotograph of FS Welded AA6061-9 wt.% SiC composite reveals the homogeneous distribution of SiC particles within the matrix.