Influence of process parameters and nanoparticles additives on the performance of IN625 - AISI316 unlike joint formed through friction stir welding

Abstract The demand for advanced structural materials necessitates components with superior mechanical properties to endure diverse loads. Dissimilar joints like IN625 and AISI316 combine unique attributes, offering significant potential. However, achieving reliable joints with optimal performance under unreliable circumstances remains a critical challenge in material engineering. This study investigated the impact of process parameters and nanoparticle reinforcements on the performance of fabricated IN625 - AISI316 materials using friction stir welding (FSW). Various rotational and welding speeds were employed to optimize joint properties. Additionally, nanoparticles such as silicon carbide (SiC) and zirconium diboride (ZrB 2 ) were incorporated into the weld region to enhance performance. The results demonstrated that process parameters significantly influenced joint properties, with optimal tensile strength achieved at a rotational speed of 700 rpm and welding speed of 40 mm min −1 . Among the reinforcements, the SiC composite outperformed ZrB 2 , yielding a tensile strength of 726 MPa, compressive strength of 1786 MPa, and a maximum hardness of 232 HV. The SiC-reinforced joint also exhibited superior wear resistance, with a minimum wear rate of 1.65 × 10 − mm 3 m −1 and a coefficient of friction of 0.28. These findings underscore the transformative role of nanoparticles and process optimization in improving the performance of dissimilar FSW joints.