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<p>The development of energy-efficient and lightweight structural materials is critical for achieving sustainable and affordable energy solutions, particularly in transportation and energy-intensive engineering systems. The objective of this study is to optimize the FSW parameters of Al 5086-TiB2 through BBD method. The input parameters considered to evaluate the tensile strength and hardness of joints are pin depth, tilt angle and weight% of TiB2 powder. The addition of TiB₂ had led to an obvious improvement in mechanical properties. The enhancement could be attributed to grain refinement and a distribution of TiB₂ in the matrix. Optimal parameters such as pin depth of 0.5&#xa0;mm, a tilt angle of 3° and TiB2 powder content of 6.35 wt % significantly improved the mechanical behavior and provided tensile strength of 313.28&#xa0;MPa and hardness value of 96 Hv during friction stir welding for Al5086/TiB2 composite. The Predicted vs. Actual plot showed high correlation, thus confirming that the BBD is an appropriately accurate model for improved computer-assisted design of enhanced mechanical properties in Al 5086-TiB2 composite joints. By combining solid-state welding with statistical optimization, this study demonstrates an energy-efficient manufacturing route for producing high-performance aluminum matrix composites. The findings contribute to sustainable materials engineering by supporting lightweight design, reduced energy consumption in fabrication, and enhanced durability of components for low-carbon transportation and energy-related applications.</p>

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Energy-efficient design of friction stir welded Al 5086–TiB₂ composites using box–behnken methodology

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Indira Benjeer Budavarthi,
  • Kaladari Adarsha Kumar,
  • Anil Kumar Deepati,
  • Vijayakumar Sivasundar

摘要

The development of energy-efficient and lightweight structural materials is critical for achieving sustainable and affordable energy solutions, particularly in transportation and energy-intensive engineering systems. The objective of this study is to optimize the FSW parameters of Al 5086-TiB2 through BBD method. The input parameters considered to evaluate the tensile strength and hardness of joints are pin depth, tilt angle and weight% of TiB2 powder. The addition of TiB₂ had led to an obvious improvement in mechanical properties. The enhancement could be attributed to grain refinement and a distribution of TiB₂ in the matrix. Optimal parameters such as pin depth of 0.5 mm, a tilt angle of 3° and TiB2 powder content of 6.35 wt % significantly improved the mechanical behavior and provided tensile strength of 313.28 MPa and hardness value of 96 Hv during friction stir welding for Al5086/TiB2 composite. The Predicted vs. Actual plot showed high correlation, thus confirming that the BBD is an appropriately accurate model for improved computer-assisted design of enhanced mechanical properties in Al 5086-TiB2 composite joints. By combining solid-state welding with statistical optimization, this study demonstrates an energy-efficient manufacturing route for producing high-performance aluminum matrix composites. The findings contribute to sustainable materials engineering by supporting lightweight design, reduced energy consumption in fabrication, and enhanced durability of components for low-carbon transportation and energy-related applications.