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Friction stir weldingFriction stir welding (FSW) is anAA6061 advancedSiC welding technique that effectively addresses surface crack repair. This study investigates the healing of an artificial crack machine with a 2 mm square groove using an innovative technique that incorporates an aluminium filler rod in combination with SiCSiC nanoparticles to ensure complete filling of the crack. FSW was conducted on both cracked and uncracked samples to compare the impact of the repair process irrespective of welding conditions. To evaluate the success of the repair method and identify potential defects in the weld zone, a series of tests, including tensile strength, microhardness, and microstructural examinations, were performed. The results indicated that the crack repair plates demonstrated higher mechanical performance compared to uncracked samples. However, some defects were observed during scanning electron microscopy (SEM) analysis, leading to a discussion on their implications for the overall integrity of the weld. This study highlights the effectiveness of the modified FSW technique in repairing cracks in 6061-T6 aluminium alloy6061-T6 aluminium alloy, suggesting a promising approach for enhancing the reliability and performance of crack healingCrack healing demanding applications.

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A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles

  • 会议论文

  • 发表日期：

    2025年

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  • Ahmad H. Bawagnih,
  • Ahmed Ali Gad El-Mawla,
  • Fadi Al-Badour,
  • Filmon Surafiel,
  • Rami K. Suleiman,
  • Necar Merah

摘要

Friction stir weldingFriction stir welding (FSW) is anAA6061 advancedSiC welding technique that effectively addresses surface crack repair. This study investigates the healing of an artificial crack machine with a 2 mm square groove using an innovative technique that incorporates an aluminium filler rod in combination with SiCSiC nanoparticles to ensure complete filling of the crack. FSW was conducted on both cracked and uncracked samples to compare the impact of the repair process irrespective of welding conditions. To evaluate the success of the repair method and identify potential defects in the weld zone, a series of tests, including tensile strength, microhardness, and microstructural examinations, were performed. The results indicated that the crack repair plates demonstrated higher mechanical performance compared to uncracked samples. However, some defects were observed during scanning electron microscopy (SEM) analysis, leading to a discussion on their implications for the overall integrity of the weld. This study highlights the effectiveness of the modified FSW technique in repairing cracks in 6061-T6 aluminium alloy6061-T6 aluminium alloy, suggesting a promising approach for enhancing the reliability and performance of crack healingCrack healing demanding applications.