The Optimization of Gap Width Size During Friction Stir Welding of AA 6061-T6 with Al2O3 Particle Reinforcement

In the present work, the groove width size optimization of the AA6061-T6 plate filled with Al2O3 powder particles was established. The numerical and experimental analyses were performed to obtain the sound quality of the joint with optimum groove size. The thermal model predicts that the weld model’s temperature increases when the groove width increases. Also, the volume fraction (Level set) model predicts that the Al2O3 volume fraction beneath the shoulder surface increases when the groove width size increases. Moreover, from the experimental analysis, the optical micrograph of the welded sample revealed that the defect-free weld surface was obtained when the groove width was 1 mm on each plate. Also, the SEM (scanning electron microscopy) and EDS (energy dispersive spectroscopy) results of the weld specimen revealed the powder particles and oxygen (O) element availability in the stir zone. The tensile and yield strength of the reinforced specimen was 7 and 20% higher than the unreinforced AA6061-T6 weld plate when the groove width was 1 mm on each plate. Also, the maximum hardness (130 HV0.2) was achieved by the W1 weld specimen at the stir zone region.