Integration of ceramic reinforcements in AA5083 composites for enhanced mechanical and thermal properties in friction stir welding

Abstract This study investigates the mechanical and thermal properties of friction stir welded (FSW) AA5083 composites reinforced with silicon carbide (SiC) and boron carbide (B4C) at varying concentrations (2 wt%, 4 wt%, 6 wt%, and 8 wt%). Composites were fabricated using stir casting, followed by friction stir welding (FSW) under controlled parameters (1000 rpm, 60 mm min −1 ). The results revealed a notable increase in mechanical performance with reinforcement: the 6 wt% SiC + 6 wt% B4C composite achieved the highest ultimate tensile strength of 365 MPa and hardness of 122 HV. Fatigue life improved from 1.2 million cycles (unreinforced) to 2.4 million cycles (8 wt% hybrid reinforced), while fracture toughness decreased from 32 MPa√m to 18 MPa√m as reinforcement increased. Thermal analysis indicated that welding temperature rose from 450 °C (unreinforced) to 530 °C (8 wt% hybrid), enhancing material flow but risking grain coarsening. Optimal performance was achieved at a 6 wt% reinforcement, balancing strength, ductility, and thermal stability. These findings demonstrate the effectiveness of hybrid ceramic reinforcement in enhancing AA5083 composites for structural applications in the aerospace, marine, and automotive industries.