Enhanced structural integrity and tribological performance of Al6061–Al6082 alloys reinforced with TiB2 and Al2O3 via friction stir welding

Abstract Aluminum alloys are widely utilized in aerospace and marissne industries due to their excellent strength-to-weight ratio and durability in demanding environments. This study aims to develop high-performance aluminum matrix composites (AMCs) with enhanced strength, wear resistance, and mechanical properties to withstand extreme temperatures, high humidity, and corrosive conditions. Dissimilar friction stir welding (FSW) was employed to join Al6061 and Al6082 alloys, incorporating titanium diboride (TiB₂) and aluminum oxide (Al₂O₃) reinforcement in the weld nugget zone (WNZ) region. The results demonstrated that the Al6061–Al6082/TiB₂ composite exhibited a significantly reduced wear rate of 7 × 10⁻ 3 mm 3 /m and a low coefficient of friction of 0.24. Additionally, the FSW-processed Al6061–Al6082/TiB₂ material recorded the highest tensile strength (364 MPa) and hardness (100 HV), surpassing other tested materials. The enhanced mechanical properties were attributed to grain refinement induced by FSW and the strengthening effect of TiB₂ particles. This work provides valuable insights into reinforcing aluminum alloys for structural applications in harsh environments, contributing to the advancement of friction stir welding and composite material engineering.