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<p>This study examined the effects of adding alumina nanoparticles on the mechanical and metallurgical properties of friction stir welding for dissimilar aluminum alloys 6061-T6 and 5083. A key challenge in this process is achieving a uniform dispersion of nanoparticles within the weld zone while preventing their agglomeration in the matrix phase. A two-pass welding technique was employed to address this issue. The findings indicated that samples subjected to two-pass welding exhibited improved nanoparticle distribution compared to those welded in a single pass. Increasing the nanoparticle volume fraction and utilizing two welding passes resulted in significant structural changes, leading to average increases of 31.5% in tensile strength, 40% in bending strength, and 32% in weld zone hardness. Furthermore, a 3D finite element thermal–mechanical model based on a coupled Eulerian–Lagrangian approach was developed to explore how the number of welding passes affects heat distribution. To validate the simulation model, the temperature and maximum spindle torque results from the first and second welding passes were compared with experimental data, demonstrating a strong correlation. The study revealed that increasing the number of welding passes from one to two intensified the thermal gradient across various zones. In the first pass, the temperature distribution was skewed toward the retreating side, while reversing the tool rotation during the second pass led to a more symmetrical heat distribution between the advancing and retreating sides.</p>

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Experimental and Numerical Investigation of Single and Double Pass Friction Stir Welding of Dissimilar Aluminum Alloys 6061-T6 and 5083 with the Addition of Al2O3

  • 期刊论文

  • 发表日期：

    2025年4月25日

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  • Mohammad Karimi Ivanaki,
  • Esmaeil Poursaeidi,
  • Davood Afshari

摘要

This study examined the effects of adding alumina nanoparticles on the mechanical and metallurgical properties of friction stir welding for dissimilar aluminum alloys 6061-T6 and 5083. A key challenge in this process is achieving a uniform dispersion of nanoparticles within the weld zone while preventing their agglomeration in the matrix phase. A two-pass welding technique was employed to address this issue. The findings indicated that samples subjected to two-pass welding exhibited improved nanoparticle distribution compared to those welded in a single pass. Increasing the nanoparticle volume fraction and utilizing two welding passes resulted in significant structural changes, leading to average increases of 31.5% in tensile strength, 40% in bending strength, and 32% in weld zone hardness. Furthermore, a 3D finite element thermal–mechanical model based on a coupled Eulerian–Lagrangian approach was developed to explore how the number of welding passes affects heat distribution. To validate the simulation model, the temperature and maximum spindle torque results from the first and second welding passes were compared with experimental data, demonstrating a strong correlation. The study revealed that increasing the number of welding passes from one to two intensified the thermal gradient across various zones. In the first pass, the temperature distribution was skewed toward the retreating side, while reversing the tool rotation during the second pass led to a more symmetrical heat distribution between the advancing and retreating sides.