Multi-objective optimization of friction stir welding parameters using desirability approach to join Al/SiC_p metal matrix composites

Silicon carbide particulate （SiCp） reinforced cast aluminium （A1） based metal matrix composites （MMCs） have gained wide acceptance in the fabrication of light weight structures requiring high specific strength, high temperature capability and good wear resistance. Friction stir welding （FSW） process parameters play major role in deciding the performance of welded joints. The ultimate tensile strength, notch tensile strength and weld nugget hardness of friction stir butt welded joints of cast A1/SiCp MMCs （AA6061 with 20% （volume fraction） of SiCp） were investigated. The relationships between the FSW process parameters （rotational speed, welding speed and axial force） and the responses （ultimate tensile strength, notch tensile strength and weld nugget hardness） were established. The optimal welding parameters to maximize the mechanical properties were identified by using desirability approach. From this investigation, it is found that the joints fabricated with the tool rotational speed of 1370 r/min, welding speed of 88.9 mm/min, and axial force of 9.6 kN yield the maximum ultimate tensile strength, notch tensile strength and hardness of 265 MPa, 201 MPa and HV 114, respectively.

Phase evolution in AlSi20/8009 aluminum alloy during high temperature heating near melting point and cooling processes

The AlSi20/8009 aluminum alloy was heated to high temperatures near the melting point and cooled to investigate the effect of external Si addition on the phase evolution of Al12(Fe,V)3 Si dispersion. Differential scanning calorimeter, scanning electron microscope, energy dispersive spectrometer and X-ray diffractometer were employed.The results showed that Al12(Fe,V)3 Si and Si phases evolved into a needle-like Al4.5 Fe Si phase and a nano-sized V-rich phase during holding the alloy at 580-600℃. With increasing holding temperature to 620-640℃, Al4.5 Fe Si and nano-sized V-rich phases evolved reversibly into Al12(Fe,V)3 Si and Si phases, of which Al12(Fe,V)3 Si occupied a coarse and hexagonal morphology. During the alloy(after holding at 640 ℃) furnace cooling to 570 ℃ or lower, Si and Al12(Fe,V)3 Si phases evolved into strip-like Al4.5 Fe Si and the V-rich phases, which is a novel formation route for Al4.5 Fe Si phase different from Al-Fe-Si ternary system.