Influence of nano fly ash on wear behavior of friction stir weld joints of Al6063/nano fly ash composites

Abstract

Abstract The manufacturing industries attracted aluminium metal matrix composites (AMCs) to utilize in the modern spectrum of applications. Inexpensive particulate reinforced composites are exhibiting superior qualities at reduced costs. Fly ash is an industrial waste that can be adopted as reinforcement, particularly for aluminium matrix materials. Friction stir welding (FSW) is best suitable to weld aluminum-based materials. In this work, the Al6063/nano fly ash composites with 0, 1, 2, and 3% wt. of nano fly ash were fabricated through ultrasonic-assisted stir casting. Consequently, FSW joints were obtained for the fabricated composites by considering rotational tool speed and transverse tool speed as welding parameters. Wear analysis carried on weld beads of composites through the pin on disc equipment. The nano fly ash addition in the composites results in increased wear resistance in the FSW joints. Higher wear resistance was achieved with increased reinforcement inclusion. Increased tool feed rate also enhances the wear resistance of FSW joints. It can be concluded that the nano fly ash particles are the most influential in improving the mechanical properties of the AMC weld beads, and FSW is the better option to weld aluminum composites.