Fatigue properties of friction stir welded particulate reinforced aluminium matrix composites

Few papers have discussed the friction stir welding (FSW) of particulate reinforced aluminium matrix composites and most of them focused on the set-up of the welding process parameters and their effect on microstructure, hardness and tensile behaviour. The aim of this study was to investigate the fatigue resistance of FSW joints on an as-cast particulate reinforced aluminium based composite (AA6061/22 vol.%/Al₂O_3p). The welding process was performed using different process parameters, also investigating their effect on joint microstructure. The mechanical properties of the FSW composites were compared with those of the base material and the results were correlated to the microstructural modifications induced by the FSW process on the aluminium alloy matrix and the ceramic reinforcement. FSW reduced the size of both particle reinforcement and aluminium grains, and also led to a significant increase in interparticle matrix microhardness, for all process parameters. The FSW specimens belonging to a different set of parameters, tested without any post-weld heat treatment, exhibited a very high joint efficiency (ranging from 90% to 99%) with respect to the ultimate tensile strength of the base material. The stress controlled fatigue test showed a high spread both for the base and FSW composites. Statistical analysis disclosed that all FSW specimens belonging to different process parameters showed apparently slightly worse fatigue behaviour than that of the base composite. Statistical processing applied to the different welding parameters revealed that all the welded specimens belonged to the same population. Therefore it can be concluded that the parameters used produced joints with similar microstructure and comparable fatigue behaviour. The slight difference in the fatigue behaviour of the FSW specimens whose process parameters differed form those of the unwelded composite was explained by the different microstructural homogeneity in the transition from the base to the FSW zone.