Friction-stir welding of aluminum alloy with an iron-based metal as reinforcing material

The fabrication of a durable and usable aluminum matrix composite poses a challenge because it is hard to obtain defect-free welds by using conventional fusion welding methods. The development of friction-stir welding (FSW) provides improved microstructure modification. As there are no melting problems associated with it, liquid-solid reactions are eliminated. The objective of this study was to attempt FSW of an AA6061 alloy reinforced with an iron-based metal and to determine the properties of the joints. The effects of FSW parameters, especially the tool rotation speed, are presented first. Then, the application of the technique in manufacturing and microstructure modification of particle-reinforced composite materials is discussed. Finally, interfacial microstructural changes and the associated mechanical properties are evaluated