Investigation on effects of nano-reinforcement on the mechanical properties, fatigue, and microstructural analysis of dissimilar AA6061- Mg AZ31B weld joints

Abstract Weld joints have been subject to substantial improvement in mechanical durability and wear resistance in recent years. This research work challenge can be answered by incorporating nano-materials into the weld zone. Mechanical and metallurgical aspects of friction stir welded (FSW) butt joints made of AA6061 aluminum and Mg AZ31B alloys have been examined in this work, both with and without the use of naturally derived biochar nanoparticles. The biochar particle was extracted from rice husk. Throughout the whole weld joint manufacturing process, a tool with a rotational speed of 1400 rpm, a welding speed of 40 mm min −1 , and a tapered pin profiled tool were employed. During the joint fabrication process, the constant axial load of 7 kN, plunge depth of 0.2 mm, and constant dwell time of 0.3 s were also maintained. In order to improve the mechanical attributes of the weld joints, different wt% of biochar such as 1%, 2%, and 3%, were applied at the interface region of the weld joints. The experimental results revealed that the percentage of reinforced nano-materials plays a significant effect in improving the weld joint qualities. The testing results of reinforced friction stir-welded joint qualities were compared to those of simple friction stir welded joints made without and with adding the nanoparticles. The best results were obtained when 2 wt% of biochar particles was added to the weld interface region. The presence of biochar nano-particles, in addition to their contribution to increased grain refinement in the weld nugget region, was also seen in the region. It was discovered that the event distribution of particles at the nugget zone significantly enhanced the mechanical and wear resistance qualities of the weld joints that were manufactured. The optical microscope was used to analyze the microstructures in the weld nugget region, and a scanning electron microscope (SEM) was utilized to examine the fracture analysis of the tensile samples. The presence of 2 wt% biochar particles in the weld nugget region resulted in a considerable increase in the mechanical characteristics of the weld connections. The ultimate tensile strength, hardness, and yield strength of the weld nugget results 197 MPa, 173 HV, 163 MPa. Overall, when compared to the qualities of the base material and plain weld joints. The mechanical properties and wear resistance of the weld joints have improved significantly. When biochar particles were used as reinforcement particles during the fabrication phase of the joint, a mechanism for pinning was observed in the weld microstructure.