Comparative analysis of fly ash cenosphere and copper reinforcements in friction stir welded AA6082-T6 alloy

Abstract This study conducts a comparative analysis of friction stir welded (FSW) AA6082-T6 alloy reinforced with fly ash cenospheres (FAC) and copper particles, focusing on enhancing mechanical properties and microstructure. The research’s novelty lies in exploring the unique effects of sustainable fly ash cenospheres, which are lightweight and eco-friendly, alongside copper, known for superior thermal and electrical properties, on the weld quality of AA6082-T6. This green approach reduces environmental impact while boosting material performance. The analysis encompasses microstructure, tensile strength, hardness, and wear resistance, aiming to understand how each reinforcement’s morphology and distribution affect weld integrity. Results reveal that AA6082-T6/Cu joints achieved a refined grain structure with an Average Grain Size (AGS) of 7.6 μm and a tensile strength of 288 MPa, while FAC-reinforced joints showed a lower tensile strength of 176 MPa with a coarser AGS of 9.3 μm. EBSD analysis confirmed significant grain refinement in copper-reinforced welds, enhancing microhardness and wear resistance. These findings provide valuable insights for optimizing sustainable reinforcement strategies in FSW applications, especially for aerospace and automotive components.