Inertia-friction welding of SiC-reinforced 8009 aluminium

Inertia-drive friction welding (IFRW) of an 8009 Al alloy (Al-8.5 Fe-1.7 Si-1.3 V, wt%) reinforced with 11 volume per cent SiC particles (8009/SiC/11_p) has been investigated. Inertia-drive friction welds were made with constant energy at two levels of axial force. The microstructures of the base material and the welds were characterized using optical and scanning electron microscopy, while the mechanical properties were evaluated using microhardness and tensile testing. Examination of weld sections revealed that the hot deformation experienced during welding produced a homogenized microstructure with a uniform distribution of SiC particles along the bond line. No evidence of a chemical reaction between the SiC and the matrix was found in any of the welds, but cracking of some of the larger SiC particles was observed in the base material as well as in the IFR welds. The average microhardness of the various heat-and-deformation affected zones (HDZs) of the welds did not vary greatly from that of the base material, and no weld induced weak regions were discerned. The room-temperature (RT) tensile strength of the IFR welds exceeded 90 per cent of the base material. The weld tensile specimens failed at the outer edge of the HDZ for all of the welds tested. The fracture surface of the 8009 matrix of tensile samples for both the base material and the welds exhibited a dimpled appearance indicating a ductile failure, while fracture through the SiC appeared to occur in a brittle fashion. IFRW has proven effective in joining 8009/SiC/11_p with little loss in RT hardness and tensile properties.